Electric concrete vehicle systems and methods

ABSTRACT

A concrete mixer truck includes a chassis, a plurality of tractive assemblies coupled to the chassis, a mixing drum rotatably coupled to the chassis, the mixing drum defining an internal volume configured to contain material and an aperture through which the material can enter and exit the internal volume, an energy storage device positioned at a rear end of the chassis and configured to provide electrical energy, and an electromagnetic device electrically coupled to the energy storage device, where the electromagnetic device is configured to receive the electrical energy from the energy storage device and provide mechanical energy to drive at least one of the plurality of tractive assemblies to propel the concrete mixer truck.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

The present application claims priority to and the benefit of U.S.Provisional Application No. 62/830,038, filed Apr. 5, 2019, U.S.Provisional Application No. 62/830,108, filed Apr. 5, 2019, U.S.Provisional Application No. 62/830,256, filed Apr. 5, 2019, U.S.Provisional Application No. 62/830,262, filed Apr. 5, 2019, and U.S.Provisional Application No. 62/830,267, filed Apr. 5, 2019, all of whichare incorporated herein by reference in their entireties.

BACKGROUND

Concrete mixer trucks are configured to receive, mix, and transport wetconcrete or a combination of ingredients that when mixed form wetconcrete to a job site. Concrete mixing vehicles include a rotatablemixing drum that mixes the concrete disposed therein. Concrete mixertrucks are normally driven by an onboard internal combustion engine.

In conventional, internal combustion engine concrete mixer trucks, theconcrete mixer trucks may be relatively quickly and easily refueled. Incontrast, the resupplying of an exclusively electric-powered concretemixer truck requires a charging of the battery module used to power thevehicle. With the current state of battery technology, and in light ofthe significant power requirements of a concrete mixer truck, rechargingof the battery module is time consuming process, which may interferewith the availability of the concrete mixer for use.

Accordingly, it would be advantageous to provide a battery module andbattery module removal assembly that would allow the battery module tobe easily and quickly removed from the concrete mixer truck.

SUMMARY

One embodiment of the present disclosure is a concrete mixer truck. Theconcrete mixer truck includes a chassis, a plurality of tractiveassemblies coupled to the chassis, a mixing drum rotatably coupled tothe chassis, the mixing drum defining an internal volume configured tocontain material and an aperture through which the material can enterand exit the internal volume, an energy storage device positioned at arear end of the chassis and configured to provide electrical energy, andan electromagnetic device electrically coupled to the energy storagedevice, where the electromagnetic device is configured to receive theelectrical energy from the energy storage device and provide mechanicalenergy to drive at least one of the plurality of tractive assemblies topropel the concrete mixer truck.

In some embodiments, at least one of the plurality of tractiveassemblies is a rear axle assembly, where a center of gravity of theenergy storage device is positioned rearward of the rear axle assembly.

In some embodiments, the electromagnetic device is configured togenerate electrical energy to charge the energy storage device.

In some embodiments, the concrete mixer truck further includes a trailercoupled to the rear end of the chassis and configured to be towed by theconcrete mixer truck, the trailer includes a frame and a plurality oftractive assemblies, where the energy storage device is coupled to theframe of the trailer.

In some embodiments, the trailer is releasably coupled to the rear endof the chassis in a fixed position and orientation relative to thechassis of the concrete mixer truck.

In some embodiments, the energy storage device includes a frame and oneor more battery assemblies, the frame configured to support the one ormore battery assemblies.

In some embodiments, the energy storage device further includes acooling system configured to remove thermal energy from the one or morebattery assemblies.

In some embodiments, the concrete mixer truck is a front dischargeconcrete mixer truck, the concrete mixer truck further includes a chuteassembly positioned at a front end of the concrete mixer truck.

In some embodiments, the concrete mixer truck further includes anaccessory module, the accessory module includes one or more powertransfer devices, where the electromagnetic device is further configuredto provide mechanical energy to operate the accessory module.

Another embodiment of the present disclosure is a concrete mixer truck.The concrete mixer truck includes a frame, a cab coupled to the frame, amixing drum coupled to the frame, and a power plant module coupled tothe frame. The power plant module includes an electromagnetic deviceelectrically coupled to a battery module, the battery module configuredto store electrical energy and positioned at a rear end of the concretemixer truck such that a weight of the battery module offsets a weight ofthe cab, a weight of the power plant module, and a weight of the mixingdrum, the electromagnetic device configured to receive electrical energyfrom the battery module and provide mechanical energy, and atransmission coupled to the electromagnetic device and configured totransfer a first portion of the mechanical energy from theelectromagnetic device to at least one of a plurality of tractiveassemblies to propel the concrete mixer truck.

In some embodiments, at least one of the plurality of tractiveassemblies is a rear axle assembly, where a center of gravity of theenergy storage device is positioned rearward of the rear axle assembly.

In some embodiments, the electromagnetic device is configured togenerate electrical energy to charge the energy storage device.

In some embodiments, the energy storage device includes a frame and oneor more battery assemblies, the frame configured to support the one ormore battery assemblies.

In some embodiments, the energy storage device further includes acooling system configured to remove thermal energy from the one or morebattery assemblies.

In some embodiments, the concrete mixer truck further includes anaccessory module coupled to the transmission, the accessory moduleincludes one or more power transfer devices, where the transmission isconfigured to transfer a portion of the mechanical energy from theelectromagnetic device to the accessory module.

In some embodiments, the concrete mixer truck further includes a trailercoupled to the rear end of the frame and configured to be towed by theconcrete mixer truck, the trailer includes a frame and a plurality oftractive assemblies, where the battery module is coupled to the frame ofthe trailer.

Yet another embodiment of the present disclosure is a battery system fora concrete mixer truck. The battery system includes a frame and one ormore battery assemblies, where the battery system is coupled to a rearend of the concrete mixer truck such that a center of gravity of thebattery system is positioned rearward of a rear axle assembly of theconcrete mixer truck, and the battery system is configured to provideelectrical energy to one or more electromagnetic devices of the concretemixer truck, the one or more electromagnetic devices configured to driveone or more tractive assemblies of the concrete mixer truck.

In some embodiments, the system further includes a plurality ofengagement members configured to releasably couple the battery system toa frame of the concrete mixer truck.

In some embodiments, the system further includes a cooling systemconfigured to remove thermal energy from the one or more batteryassemblies.

In some embodiments, the one or more electromagnetic devices are furtherconfigured to provide charge the battery system.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will become more fully understood from the followingdetailed description, taken in conjunction with the accompanyingfigures, wherein like reference numerals refer to like elements, inwhich:

FIG. 1 is a side view of a concrete mixer truck, according to anexemplary embodiment;

FIG. 2 is a front perspective view of the concrete mixer truck of FIG.1;

FIG. 3 is another front perspective view of the concrete mixer truck ofFIG. 1;

FIG. 4 is a side perspective view of the concrete mixer truck of FIG. 1;

FIG. 5 is a side section view of the concrete mixer truck of FIG. 1;

FIGS. 6-8 are perspective views from inside a cab of the concrete mixertruck of FIG. 1, according to an exemplary embodiment;

FIGS. 9A and 9B are perspective views of the concrete mixer truck ofFIG. 1 with a chute of the concrete mixer truck in a use configuration,according to an exemplary embodiment;

FIG. 10 is a side view of a drive system of the concrete mixer truck ofFIG. 1, according to an exemplary embodiment;

FIG. 11 is a top view of the drive system of FIG. 10;

FIG. 12 is a detailed schematic view of the drive system of FIG. 10,according to an exemplary embodiment;

FIGS. 13-16 are various perspective views of an accessory module of theconcrete mixer truck of FIG. 1, according to an exemplary embodiment;

FIG. 17 is a diagram of a serpentine belt assembly of the accessorymodule of FIG. 13, according to an exemplary embodiment;

FIG. 18 is a detailed schematic view of the drive system of FIG. 10,according to another exemplary embodiment;

FIG. 19 is a detailed schematic view of variators of the drive system ofFIG. 18, according to an exemplary embodiment;

FIG. 20 is a detailed schematic view of variators of the drive system ofFIG. 18, according to another exemplary embodiment;

FIG. 21 is a schematic diagram of a control system of the concrete mixertruck of FIG. 1, according to an exemplary embodiment;

FIG. 22 is a detailed schematic view of the drive system of FIG. 12configured in an active neutral mode of operation, according to anexemplary embodiment;

FIG. 23 is a detailed schematic view of the drive system of FIG. 12configured in a low range mode of operation, according to an exemplaryembodiment;

FIG. 24 is a detailed schematic view of the drive system of FIG. 12configured in a mid range mode of operation, according to an exemplaryembodiment;

FIG. 25 is a detailed schematic view of the drive system of FIG. 12configured in a high range mode of operation, according to an exemplaryembodiment;

FIG. 26 is a detailed schematic view of the drive system of FIG. 12configured in an intermediate shift mode of operation, according to anexemplary embodiment;

FIG. 27 is a detailed schematic view of the drive system of FIG. 12configured in a low speed reverse mode of operation, according to anexemplary embodiment;

FIG. 28 is a detailed schematic view of the drive system of FIG. 12configured in a mid speed reverse mode of operation, according to anexemplary embodiment;

FIGS. 29, 30A, and 30B are perspective views of a frame of a batterymodule of the concrete mixer truck of FIG. 1, according to an exemplaryembodiment;

FIGS. 31A and 31B are views of a mounting assembly for the batterymodule, according to an exemplary embodiment;

FIGS. 32A-40 illustrate removal assemblies for the battery module,according to various exemplary embodiments;

FIGS. 41-42B illustrate the battery module configured as a trailer,according to various exemplary embodiments;

FIGS. 43A-43C illustrate the battery module configured as a frame slideout, according to various exemplary embodiments;

FIG. 44 is a perspective view of the battery module, according to anexemplary embodiment;

FIG. 45 is a view of a removal assembly for a secondary battery,according to an exemplary embodiment;

FIG. 46A is a block diagram of the concrete mixer truck having anengine-defined primary power source, according to an exemplaryembodiment;

FIG. 46B is a block diagram of the concrete mixer truck of FIG. 46A thathas been converted to include a battery module-based primary powersource, according to an exemplary embodiment;

FIG. 47A is a block diagram of a concrete mixer truck having anengine-defined primary power source, according to an exemplaryembodiment;

FIG. 47B is a block diagram of the concrete mixer truck of FIG. 47A thathas been converted to include a battery module-based primary powersource, according to an exemplary embodiment;

FIG. 48 is a block diagram of a power management system, according to anexemplary embodiment;

FIG. 49 is a perspective view of the battery module, according to anexemplary embodiment;

FIG. 50 is a rear perspective view of the concrete mixer truck of FIG.1, according to an exemplary embodiment;

FIGS. 51-53 are perspective views of battery assemblies of a batterymodule on the frame of FIGS. 29-30B, according to an exemplaryembodiment;

FIGS. 54-56 are perspective views of the power management system of thebattery module arranged on the frame of the battery module, according toan exemplary embodiment;

FIG. 57 is a topology of a traction inverter circuit, according to anexemplary embodiment;

FIGS. 58-62A illustrate topologies of a power management system circuit,according to an exemplary embodiments;

FIGS. 62B-62E illustrate various operational modes of the powermanagement system circuit of FIG. 58, according to exemplaryembodiments;

FIGS. 63-66 are topologies of a power management system circuit,according to exemplary embodiments;

FIG. 67 is a block diagram illustrating the flow of electrical energywithin the power management system of FIG. 48 during a chargingoperation mode, according to an exemplary embodiment;

FIG. 68 is a block diagram illustrating the flow of electrical energywithin the power management system of FIG. 48 during a transportoperation mode, according to an exemplary embodiment;

FIGS. 69A-69D are block diagrams illustrating the flow of electricalenergy within the power management system of FIG. 48 during variousmixing operation modes, according to exemplary embodiments; and

FIGS. 70 and 71 are perspective views of a cooling system of the batterymodule arranged on the frame of the battery module, according to anexemplary embodiment.

DETAILED DESCRIPTION

Before turning to the figures, which illustrate the exemplaryembodiments in detail, it should be understood that the presentapplication is not limited to the details or methodology set forth inthe description or illustrated in the figures. It should also beunderstood that the terminology is for the purpose of description onlyand should not be regarded as limiting.

Overview

According to an exemplary embodiment, a concrete mixer truck is shown.The concrete mixer truck includes a chassis, a cab coupled the chassisnear a front end of the chassis, and a drum assembly coupled to thechassis and extending behind the mixing drum assembly. The drum assemblyincludes a mixing drum rotatably coupled to the chassis by a frontpedestal and a rear pedestal. The mixing drum defines an aperture near afront end of the drum assembly such that the concrete mixer truck isconfigured as a front discharge concrete mixer truck. The drum assemblyfurther includes a hopper configured to direct concrete through theaperture and into the mixing drum and a chute configured to directconcrete dispensed from the mixing drum onto a desired location near thetruck.

The concrete mixer truck further includes a drive system configured topropel the concrete mixer truck and to drive the various systems of theconcrete mixer truck. The drive system includes a power plant modulecoupled to the chassis. The power plant module includes a firstelectromagnetic device and a second electromagnetic device coupled tothe transmission. The first and second electromagnetic devices are eachconfigured to consume electrical energy and provide rotationalmechanical energy to the transmission. The drive system further includesa series of tractive assemblies including a front axle assembly and apair of rear axle assemblies. The front axle assembly and the rear axleassemblies are driven by the power plant module and engage a supportsurface (e.g., the ground) to propel the vehicle.

The drive system further includes an accessory module configured todrive other functions of the concrete mixer truck. A power take off(PTO) shaft transfers rotational mechanical energy from the power plantmodule to the accessory module. The accessory module includes pumps,compressors, and an alternator. The pumps consume the rotationalmechanical energy from the PTO shaft and provide pressurized hydraulicfluid to drive actuators that operate the mixing drum, the hopper, andthe chute. The compressors consume the rotational mechanical energy fromthe PTO shaft and provide (a) compressed air to drive braking andsuspension components of the drive system and (b) compressed refrigerantfor use in a climate control system of the concrete mixer truck. Thealternator consumes the rotational mechanical energy from the PTO shaftand provides electrical energy for use throughout the concrete mixertruck.

The concrete mixer truck includes a battery module configured to storeand provide electrical energy. The battery module includes a series ofindividual battery assemblies electrically coupled to one another andconfigured to store electrical energy. The batteries are charged withelectrical energy from an external power source (e.g., a generator,mains power from a power grid, etc.). The electrical energy from thebattery assemblies is used to power the electromagnetic devices,propelling the concrete mixer truck and driving the accessory module.

Concrete Mixer Truck

According to the exemplary embodiment shown in FIGS. 1-4, a vehicle,shown as concrete mixer truck 10, is illustrated. Concrete mixer truck10 may be a front discharge or rear discharge concrete mixer truck,configured to transport concrete from a mixing location to a point ofuse. In other embodiments, concrete mixer truck 10 is another type ofvehicle (e.g., a refuse vehicle, a skid-loader, a telehandler, a plowtruck, a boom truck, a fork lift, a scissor lift, a military vehicle,etc.). As shown in FIGS. 1-4, the concrete mixer truck 10 is a frontdischarge concrete mixer truck. According to an alternative embodiment,the concrete mixer truck 10 is a rear discharge concrete mixer truck.The concrete mixer truck 10 includes a chassis 20 configured to supportthe various components that transport concrete. The chassis 20 has afront end 22 and a rear end 24 defined with respect to the direction oftravel of the concrete mixer truck 10. The chassis 20 includes a pair offrame rails 30 coupled with intermediate cross members, according to anexemplary embodiment. As shown in FIG. 1, the frame rails 30 extend in agenerally-horizontal and longitudinal direction (e.g., extend within 10degrees of perpendicular relative to a vertical direction, extend withinten degrees of parallel relative to a ground surface when concrete mixertruck 10 is positioned on flat ground, etc.) between the front end 22and the rear end 24. The frame rails 30 may be elongated “C”-channels ortubular members, according to various exemplary embodiments. In otherembodiments, the frame rails 30 include another type of structuralelement (e.g., monocoque, a hull, etc.). In still other embodiments, theframe rails 30 include a combination of elongated C-channels, tubularmembers, a monocoque element, and/or a hull element.

According to the exemplary embodiment shown in FIGS. 1-4, the concretemixer truck 10 includes an operator cabin or front cabin, shown as cab100. The cab 100 is coupled to the frame rails 30 near the front end 22.The cab 100 is configured to house one or more operators duringoperation of the concrete mixer truck 10 (e.g., when driving, whendispensing concrete, etc.). The cab 100 may include various componentsthat facilitate operation and occupancy of the concrete mixer truck 10(e.g., one or more seats, a steering wheel, control panels, screens,etc.).

The concrete mixer truck 10 further includes an assembly for mixing,storing, and dispensing concrete, shown as drum assembly 200. The drumassembly 200 includes a concrete mixing drum, shown as mixing drum 202.The mixing drum 202 extends longitudinally along the length of concretemixer truck 10. According to an exemplary embodiment, the mixing drum202 is angled relative to frame rail 30 (e.g., when viewed from the sideof concrete mixer truck 10, etc.). The mixing drum 202 may include afront end that extends over the cab 100. As shown in FIG. 5, the frontend of the mixing drum 202 defines an aperture 204 through which amixture, such as a concrete mixture (e.g., cementitious material,aggregate, sand, etc.), can enter and exit an internal volume 206 of themixing drum 202. The mixing drum 202 may include a mixing element (e.g.,fins, etc.) positioned within the internal volume 206. The mixingelement may be configured to (i) agitate the contents of mixture withinthe mixing drum 202 when the mixing drum 202 is rotated in a firstdirection (e.g., counterclockwise, clockwise, etc.) and (ii) drive themixture within the mixing drum 202 out through the aperture 204 when themixing drum 202 is rotated in an opposing second direction (e.g.,clockwise, counterclockwise, etc.).

As shown in FIG. 1, the mixing drum 202 is coupled to frame rails 30with a front drum pedestal, shown as front pedestal 210, and a rear drumpedestal, shown as rear pedestal 212. The mixing drum 202 may berotatably coupled to the front pedestal 210 (e.g., with a plurality ofwheels or rollers, etc.). A motor or driver assembly, shown as drumdriver 214, couples the mixing drum 202 to the rear pedestal 212. Inother embodiments, the mixing drum 202 is otherwise coupled to the framerails 30. The drum driver 214 is configured to apply a torque to themixing drum 202 to rotate the mixing drum 202 relative to the chassis20. The drum driver 214 may be configured to selectively rotate themixing drum 202 clockwise or counterclockwise, depending on the mode ofoperation of the concrete mixer truck 10 (e.g., whether concrete isbeing mixed or dispensed).

A hopper assembly, shown as hopper 220, and a chute assembly, shown aschute 222, are positioned near the aperture 204. The hopper 220 acts asan inlet to the drum assembly 200 and is used to direct material throughthe aperture 204 and into the internal volume 206. The chute 222 acts asan outlet of the drum assembly 200 and is used to direct concretedispensed from the internal volume 206 of the mixing drum 202 to atarget location near the concrete mixer truck 10. An operator platform,shown as work platform 224, is positioned above the cab 100 near theaperture 204 and facilitates access by an operator to the aperture 204,the hopper 220, and the chute 222 for maintenance and cleaning.

Referring again to FIG. 1, the concrete mixer truck 10 includes a watertank 230. The water tank 230 is coupled to frame rails 30 and positionedbeneath the mixing drum 202, according to an exemplary embodiment. Asshown in FIGS. 1 and 4, the water tank 230 extends laterally across thewidth of the chassis 20. The water tank 230 may be used to supply waterto wash the concrete mixer truck 10 after pouring a concrete load and/orto add water to the concrete at the construction site, among other uses.

Referring to FIGS. 1 and 5, the concrete mixer truck 10 includes a drivesystem 300 that is configured to propel the concrete mixer truck 10 anddrive the other systems of the concrete mixer truck 10 (e.g., the drumdriver 214, etc.). The drive system 300 includes a power plant module,prime mover module, or driver module, shown as power plant module 302,that is configured to supply rotational mechanical energy. As shown inFIG. 5, the power plant module 302 includes a transmission 304 and afirst electrical machine, electromagnetic device, and/ormotor/generator, shown as first electromagnetic device 306 and a secondelectrical machine, electromagnetic device, and/or motor/generator,shown as second electromagnetic device 308, coupled to the transmission304. The first electromagnetic device 306 and the second electromagneticdevice 308 are each configured provide a mechanical energy input to thetransmission 304. By way of example, the first electromagnetic device306 and the second electromagnetic device 308 may be configured tosupply a rotational mechanical energy input to the transmission 304.

The drive system 300 further includes a series of tractive assembliescoupled to the chassis 20 and configured to engage a support surface(e.g., the ground) to support the concrete mixer truck 10. As shown inFIG. 1, the drive system 300 includes a first driven tractive assembly,shown as front axle assembly 500, and a pair of second driven tractiveassemblies, shown as rear axle assemblies 502. The front axle assembly500 and the rear axle assemblies 502 are coupled to the power plantmodule 302 (e.g., through drive shafts, etc.) such that the front axleassembly 500 and the rear axle assemblies 502 at least selectivelyreceive mechanical energy (e.g., rotational mechanical energy) andpropel the concrete mixer truck 10. The drive system 300 furtherincludes a pair of non-driven or non-powered tractive assemblies (e.g.,pusher axles, lift axles, tag axles, etc.), shown as pusher axleassembly 504 and tag axle assembly 506. The pusher axle assembly 504 ispositioned between the front axle assembly 500 and the rear axleassemblies 502. The tag axle assembly 506 is positioned rearward of therear axle assemblies 502. The pusher axle assembly 504 and the tag axleassembly 506 are configured to be raised and lowered to selectivelyengage the support surface (e.g., based on the loading of the concretemixer truck 10). In other embodiments, the drive system 300 includesother tractive assemblies and/or the tractive assemblies are otherwiseconfigured.

The front axle assembly 500, the rear axle assemblies 502, the pusheraxle assembly 504, and/or the tag axle assembly 506 may include brakes(e.g., disc brakes, drum brakes, air brakes, etc.), gear reductions,steering components, wheel hubs, wheels, tires, and/or other features.As shown in FIG. 1, front axle assembly 500, the rear axle assemblies502, the pusher axle assembly 504, and the tag axle assembly 506 eachinclude tractive elements, shown as wheel and tire assemblies 508. Inother embodiments, at least one of the front axle assembly 500, the rearaxle assemblies 502, the pusher axle assembly 504, and the tag axleassembly 506 include a different type of tractive element (e.g., atrack, etc.).

Referring to FIG. 5, the drive system 300 further includes an assembly,shown as accessory module 600. The accessory module 600 is configured toreceive mechanical energy (e.g., rotational mechanical energy) from thepower plant module 302 and provide energy (e.g., pressurized fluid,compressed gas, electricity, etc.) to drive other systems throughout theconcrete mixer truck 10. As shown in FIG. 5, the drive system 300includes a driveshaft, shown as power take off (PTO) shaft 602,configured to transfer rotational mechanical energy from the power plantmodule 302 to the accessory module 600. The accessory module 600 caninclude pumps (hydraulic fluid pumps, water pumps, etc.), compressors(e.g., air compressors, air conditioning compressors, etc.), generators,alternators, and/or other types of energy generation and/or distributiondevices configured to transfer the energy from the PTO shaft 602 toother systems.

As shown in FIG. 1, the drive system 300 includes a first vessel,container, reservoir, or tank, shown as air tank 604, and a secondvessel, container, reservoir, or tank, shown as hydraulic fluid tank606. The air tank 604 is configured to store compressed air (e.g., foruse in an air brake system, for use when raising and lowering the pusheraxle assembly 504 and/or the tag axle assembly 506, etc.). The hydraulicfluid tank 606 acts as a reservoir, storing hydraulic fluid for use inone or more hydraulic circuits (e.g., a circuit that includes the drumdriver 214). The air tank 604 is coupled to the chassis 20 andpositioned directly beneath the mixing drum 202. The hydraulic fluidtank 606 is coupled to a side of the rear pedestal 212. In otherembodiments, the air tank 604 and/or the hydraulic fluid tank 606 arepositioned elsewhere on the concrete mixer truck 10.

The concrete mixer truck 10 further includes an energy storage device,shown as battery module 800. The battery module 800 is coupled to theframe rails 30 near the rear end 24 of the chassis 20. In otherembodiments, the concrete mixer truck 10 includes multiple batterymodules spread throughout the concrete mixer truck 10, which cooperateto act as battery module 800. The battery module 800 includes one ormore energy storage devices (e.g., batteries, capacitors,ultra-capacitors, etc.) configured to store energy. The battery module800 is configured to provide the stored energy in the form of mechanicalenergy (e.g., rotational mechanical energy) to the first electromagneticdevice 306 and/or the second electromagnetic device 308 to power thepower plant module 302. The battery module 800 can be charged through anonboard energy source (e.g., through use of an onboard generator poweredby an internal combustion engine, by operating the first electromagneticdevice 306 and/or the second electromagnetic device 308 as generators,such as during regenerative braking, etc.) or through an external energysource (e.g., when receiving mains power from a power grid, etc.).Referring to FIG. 4, the concrete mixer truck 10 includes a connector orport, shown as charging port 802, which is configured to electricallycouple the battery module 800 to an external energy source. In someembodiments, the concrete mixer truck 10 is a purely electric vehiclethat does not include an engine and as such is driven by electricalenergy in all modes of operation. In such embodiments, the concretemixer truck 10 may not include a fuel tank.

In some embodiments, the concrete mixer truck 10 additionally oralternatively includes another type of prime mover, such as an engine.Such an engine may be configured to utilize one or more of a variety offuels (e.g., gasoline, diesel, bio-diesel, ethanol, natural gas, etc.)and output mechanical energy. Such fuels may be stored in a fuel tankonboard the concrete mixer truck 10. This mechanical energy may be useddirectly (e.g., as a rotational mechanical energy input to thetransmission 304, etc.) or converted into electrical energy that issubsequently used to charge the battery module 800 or to power the firstelectromagnetic device 306, the second electromagnetic device 308,and/or other electrical systems of the concrete mixer truck 10. In someembodiments that include an engine, one or more of the firstelectromagnetic device 306, the second electromagnetic device 308, andthe battery module 800 are omitted. Accordingly, the concrete mixertruck 10 may be a purely electric vehicle, a hybrid vehicle, or a purelyinternal combustion vehicle.

Cab

Referring to FIGS. 2,4, and 6-8, the cab 100 is shown according to anexemplary embodiment. The cab 100 includes at least one seat configuredto support an operator. In one embodiment, the cab 100 includes one seatfrom which a single operator can control the concrete mixer truck 10(e.g., a driver's seat). In another embodiment, the cab 100 includes twoseats (e.g., a driver's seat and a passenger seat). The cab 100 may beconfigured such that functions of the concrete mixer truck 10 (e.g., thedirection of rotation of the mixing drum 202, the orientation of thechute 222, etc.) are controlled from the driver's seat, from thepassenger seat, or from both. In some embodiments, one or more functionsof the concrete mixer truck 10 can be controlled from outside of the cab100 (e.g., using a panel located on the exterior of the concrete mixertruck 10, using a portable device in communication with the concretemixer truck 10 such as a smartphone, tablet, or laptop, etc.).

FIGS. 6-8 show the interior of the cab 100 from the perspective of anoperator seated in a driver's seat of the cab 100. The cab 100 includesa control interface, shown as user interface 102, that facilitatescontrol of the functions of the concrete mixer truck 10. The userinterface 102 may be configured to accept commands from an operatorand/or provide information to the operator regarding the operation ofthe concrete mixer truck 10. The user interface 102 may be operativelycoupled to a controller of the concrete mixer truck 10. The userinterface 102 can include buttons, switches, joysticks, steering wheels,pedals, levers, knobs, touchscreens, lights, screens, gauges, or otherdevices configured to receive operator inputs or provide information toan operator.

As shown in FIGS. 6-8, the user interface 102 includes a series of userinterface devices, shown as buttons 104, each configured to control oneor more functions. By way of example, the buttons 104 can control thedrum assembly 200 (e.g., the rotation speed and rotation direction ofthe mixing drum 202, the position of the hopper 220, locking orunlocking the position of the chute 222, etc.). By way of anotherexample, the buttons 104 can control the positions of the pusher axleassembly 504 and the tag axle assembly 506 (e.g., to raise or lower theaxle assemblies). By way of another example, the buttons 104 can controlthe transmission 304 (e.g., shifting gears, braking an output,controlling the speed of an output such as the PTO shaft 602, etc.). Byway of another example, the buttons 104 can control the headlights ofthe concrete mixer truck 10. By way of another example, the buttons 104can turn the concrete mixer truck 10 on or off. The cab 100 furtherincludes a user interface device, shown as joystick 106. The joystick106 can be configured to control the orientation of the chute 222 (e.g.,raising, lowering, rotating, etc.). The joystick 106 can include one ormore buttons and/or switches that control the rotation speed and therotation direction of the mixing drum 202. The user interface 102further includes a user interface device, shown as signal lever 108. Thesignal lever 108 may be configured to control a windshield wiper (e.g.,a windshield wiper speed, applying windshield wiper fluid, etc.). Thesignal lever 108 may additionally be configured to control one or moreindicators (e.g., turn signals, etc.).

The user interface 102 further includes a pair of user interfacedevices, shown as brake pedal 120 and accelerator pedal 122. The brakepedal 120 may be configured to activate a brake system of the concretemixer truck 10 (e.g., the brakes 532) when depressed. The acceleratorpedal 122 may be configured to control the drive system 300 to propelthe concrete mixer truck 10 when depressed. By way of example, a greateramount of electrical energy may be provided to the first electromagneticdevice 306 and the second electromagnetic device 308 in response to theaccelerator pedal 122 being depressed. The brake pedal 120 and theaccelerator pedal 122 may be mechanically coupled (e.g., through one ormore cables) to the systems that they control. Alternatively, the brakepedal 120 and the accelerator pedal 122 may be electrically coupled tothe systems that they control. By way of example, the brake pedal 120and the accelerator pedal 122 may be sensors, and a controller maybeconfigured to control the concrete mixer truck 10 in response to userinput detected by those sensors. The user interface further includes auser interface device, shown as steering shaft 124. The steering shaft124 may be directly coupled to a steering wheel to facilitate userinput. The steering shaft 124 may be configured to control one or moresteering components to steer the concrete mixer truck 10.

The user interface 102 further includes a user interface device (e.g., ascreen, a touchscreen, a display, etc.), shown as tablet 130. The tablet130 may be configured to display information regarding the currentoperation of the concrete mixer truck 10 (e.g., the speed of theconcrete mixer truck 10, the amount of material in the mixing drum 202,the characteristics of the material in the mixing drum 202 such asslump, the charge level of the battery module 800, etc.). The tablet 130may be a touchscreen such that the tablet 130 is configured to receiveuser inputs (e.g., user preferences, to navigate through menus, etc.).In one embodiment, the tablet 130 is removable from the cab 100 and isconfigured to communicate wirelessly with the concrete mixer truck 10such that the tablet 130 can be used to control the concrete mixer truck10 from outside of the cab 100. The user interface 102 further includesone or more indicators, shown as lights 132. The lights 132 may beconfigured to illuminate to indicate information to the operator, suchas the current configuration of the transmission 304 (e.g., a drivegear, a neutral gear, a reverse gear, a high or low speed range, etc.).

Drum Assembly

Referring to FIGS. 1-5, the drum assembly 200 is shown according to anexemplary embodiment. The mixing drum 202 is rotatably coupled to thefront pedestal 210 and the rear pedestal 212 such that the mixing drum202 rotates about an axis of rotation, shown in FIG. 5 as axis 240, thatis angled relative to the chassis 20, raising the aperture 204 relativeto a base of the mixing drum 202. Specifically, the drum assembly 200includes an annular member, shown as bearing ring 242. The bearing ring242 is fixedly coupled to the exterior of the mixing drum 202. Thebearing ring 242 has a hardened surface (e.g., formed from hardenedsteel, etc.) that engages the front pedestal 210 (e.g., one or morerollers of the front pedestal 210, etc.). In some embodiments, thehardened surface of the bearing ring 242 is centered about the axis 240.The bearing ring 242 supports a front portion of the mixing drum 202 andthe material therein, and the hardened surface of the bearing ring 242reduces wear as the mixing drum 202 rotates. The drum driver 214 iscoupled to a rear or base portion of the mixing drum 202 and a top endof the rear pedestal 212. The drum driver 214 supports a rear portion ofthe mixing drum 202 and the material therein.

As shown in FIG. 5, the drum driver 214 includes a transmission, shownas drum drive transmission 250, and a driver, shown as drum drive motor252, coupled to drum drive transmission 250. According to the exemplaryembodiment shown in FIG. 5, the drum drive motor 252 is a hydraulicmotor. In other embodiments, the drum drive motor 252 is another type ofactuator (e.g., an electric motor, etc.). The drum drive motor 252 isconfigured to provide an output torque to the drum drive transmission250, according to an exemplary embodiment, which rotates the mixing drum202 about the axis 240. As shown in FIG. 5, the drum drive transmission250 extends rearward (i.e., toward the rear end 24 of the chassis 20,toward the battery module 800, etc.) from the base portion of the mixingdrum 202, and the drum drive motor 252 extends rearward from the drumdrive transmission 250. The drum drive transmission 250 extends directlyabove the rear pedestal 212. The drum drive transmission 250 includes aplurality of gears (e.g., a planetary gear reduction set, etc.)configured to increase the turning torque applied to mixing drum 202,according to an exemplary embodiment. The plurality of gears may bedisposed within a housing.

The hopper 220 is pivotally coupled to the work platform 224 such thatthe hopper 220 is configured to rotate about a horizontal, lateral axis.Specifically, the hopper 220 is configured to move between a loweredposition, shown in FIG. 5, and a raised position above the loweredposition. In the lowered position, the hopper 220 is configured todirect material (e.g., concrete) from a source positioned above theconcrete mixer truck 10 (e.g., a batch plant) through the aperture 204and into the internal volume 206 of the mixing drum 202. The loweredposition may also facilitate transport of the concrete mixer truck 10 bylowering the overall height of the concrete mixer truck 10. In theraised position, the hopper 220 moves away from the aperture 204 andfacilitates material flowing unobstructed out of the aperture 204 andinto the chute 222. As shown in FIG. 2, the drum assembly 200 includes adriver, shown as hopper actuator 260, configured to move the hopper 220between the raised and lowered positions. The hopper actuator 260 iscoupled to the hopper 220 and the work platform 224. According to theexemplary embodiment shown in FIG. 2, the hopper actuator 260 is ahydraulic cylinder. In other embodiments, the hopper actuator 260 isanother type of actuator (e.g., a pneumatic cylinder, a lead screwdriven by an electric motor, etc.).

Referring to FIGS. 2, 3, 9A, and 9B, the chute 222 is pivotally coupledto the work platform 224 such that the chute 222 is configured to rotateabout both a vertical axis and a horizontal axis. The chute 222 includesa first chute section, shown as base section 270 that is directlypivotally coupled to the work platform 224. A second chute section,shown as folding section 272, is pivotally coupled to the distal end ofthe base section 270. Another folding section 272 is pivotally coupledto the distal end of the first folding section 272. A third chutesection, shown as removable section 274, is removably coupled to the endof the second folding section 272. The chute 222 is selectivelyreconfigurable between a storage or transport configuration, shown inFIGS. 2 and 3, and a use configuration, shown in FIGS. 9A and 9B. In thetransport configuration, the base section 270 is oriented substantiallyhorizontal and extends laterally outward. The folding sections 272 arearranged adjacent one another and extend substantially vertically. Theremovable sections 274 are removed from the folding sections 272 andstored elsewhere in the concrete mixer truck 10 (e.g., coupled to thechassis beneath the mixing drum 202, etc.). In the transportconfiguration, the chute 222 minimally obscures the view of an operatorpositioned within the cab 100. In the use configuration, the basesection 270 and the folding sections 272 are aligned with one another toform a continuous path through which material can flow. One or more ofthe removable sections 274 can be coupled to the distal end of thefolding sections 272 to increase the length of the chute 222 (e.g., todistribute concrete farther away from the aperture 204).

The drum assembly 200 includes a first driver or actuator, shown aschute height actuator 280, extending between the chute 222 and thechassis 20. Specifically, the chute height actuator 280 is pivotallycoupled to the chassis 20 near the front end 22 and the base section270. The chute height actuator 280 is configured to raise and lower thechute 222 to control the orientation of the chute 222 relative to ahorizontal plane (e.g., the ground). According to the exemplaryembodiment shown in FIG. 2, the chute height actuator 280 is a pair ofopposing hydraulic cylinders. In other embodiments, the chute heightactuator 280 is another type of actuator (e.g., a pneumatic cylinder, alead screw driven by an electric motor, etc.). In some embodiments, thechute height actuator 280 and the chute 222 are both configured torotate about the same or substantially the same vertical axis.Accordingly, the chute 222 remains at a constant or substantiallyconstant height as the chute 222 rotates about the vertical axis.

The drum assembly 200 includes a second driver or actuator, shown aschute rotation actuator 282 coupled to the base section 270 of the chute222 and the work platform 224. The chute rotation actuator 282 isconfigured to rotate the chute 222 about the vertical axis. The chuterotation actuator 282 is configured to move the distal end of the chute222 through an arc along the left, front, and right sides of the chassis20 (e.g., a 150 degree arc, a 180 degree arc, a 210 degree arc, etc.).In one embodiment, the chute rotation actuator 282 is a hydraulic motor.In other embodiments, the chute rotation actuator 282 is another type ofactuator (e.g., a pneumatic motor, an electric motor, etc.).

The drum assembly 200 further includes a series of third drivers oractuators, shown as chute folding actuators 284. The chute foldingactuators 284 are configured to rotate both (a) the first foldingsection 272 relative to the base section 270 and (b) the second foldingsection 272 relative to the first folding section 272. One pair of chutefolding actuators 284 are coupled to the base section 270 and the firstfolding section 272. Another pair of chute folding actuators 284 arecoupled to both of the folding sections 272. The chute folding actuators284 are configured to extend to move the folding sections 272 toward thetransport configuration and to retract to move the folding sections 272toward the use configuration. According to the exemplary embodimentshown in FIGS. 2 and 3, the chute folding actuators 284 are hydrauliccylinders. In other embodiments, the chute folding actuators 284 areanother type of actuator (e.g., a pneumatic cylinder, a lead screwdriven by an electric motor, etc.).

Referring to FIGS. 2-4, the work platform 224 is shown according to anexemplary embodiment. The work platform 224 is coupled to the cab 100and the front pedestal 210 (e.g., as shown in FIG. 9A). The workplatform 224 is positioned above the cab 100 such that the work platform224 minimally obscures the vision of an operator positioned within thecab 100. The work platform 224 defines a substantially flat surfaceconfigured to support an operator (e.g., for maintenance purposes, toview or access the internal volume 206 of the mixing drum 202, etc.).The work platform 224 partially surrounds the aperture 204. Tofacilitate access to the work platform 224, the drum assembly 200includes an access assembly, shown as ladder 290. The ladder 290 extendsbetween and is coupled to the chassis 20 and the work platform 224laterally outward from the cab 100. The drum assembly 200 furtherincludes a divider, shown as railing 292, configured to support andcontain operators positioned atop the work platform 224.

In operation, the concrete mixer truck 10 is configured to receivematerial (e.g., concrete, etc.), transport the material to a job sitewhere the material will be used while mixing the material, and dispensethe material in a target location at the job site. The concrete mixertruck 10 may be configured to receive material from a source positionedabove the concrete mixer truck 10, such as a concrete batch plant. Whenreceiving the material, the hopper 220 is in the lowered position andthe chute 222 is in the transport configuration. Accordingly, materialcan be deposited into the hopper 220, and the hopper 220 directs thematerial into the internal volume 206 of the mixing drum 202 through theaperture 204. While material is being added to the mixing drum 202, thedrum driver 214 may drive the mixing drum in the first direction toagitate the material and facilitate fully packing the mixing drum 202.Alternatively, the mixing drum 202 may be stationary while material isadded to the mixing drum 202. In some embodiments, the concrete mixertruck 10 remains in the same configuration both when receiving materialand when transporting material to a job site.

Once at the job site, the concrete mixer truck 10 is configured todispense the material onto a desired location (e.g., into a form, ontothe ground, etc.). The hopper 220 is rotated into the raised position bythe hopper actuator 260 (e.g., in response to the operator pressing abutton 104, etc.). The folding sections 272 of the chute 222 areextended by the chute folding actuators 284 to reconfigure the chute 222into the use configuration. An operator can then couple one or moreremovable sections 274 to the distal end of the second folding section272 to increase the overall length of the chute 222. Once the chute 222is in the use configuration, the operator can control the chute heightactuator 280 and/or the chute rotation actuator 282 to adjust theorientation of the chute 222 and thereby direct the material onto thedesired location. By way of example, the operator may control the chuteheight actuator 280 and the chute rotation actuator 282 using thejoystick 106. Once the chute 222 is in the desired orientation, theoperator can control the drum driver 214 to rotate the mixing drum 202in the second direction, expelling material through the aperture 204 andinto the chute 222. The operator may control the speed of the mixingdrum 202 to adjust the rate at which material is delivered through thechute 222. By way of example, the operator may control the speed anddirection of rotation of the drum driver 214 using one or more buttonspositioned on the joystick 106. Throughout the process of dispensing thematerial, the operator can change the location onto which the materialis dispensed by varying the orientation of the chute 222 and/or bycontrolling the drive system 300 to propel the concrete mixer truck 10.

Drive System

A primary power source of the cement mixer truck 10 is configured todirectly, or indirectly, supply the various components of the cementmixer truck 10 with the power needed to operate the concrete mixer truck10. The primary power source may be defined by any number of differenttypes of power sources. According to various embodiments, users may takeadvantage of the ability to easily and quickly substitute a first typeof primary power source with a second, different type of power source toretrofit the concrete mixer truck 10 with a new, more efficient primarypower source one or more times over the life of the concrete mixer truck10, so as to take advantage of such options as they become available.

According to some embodiments, the primary power source may comprise aninternal combustion engine configured to utilize one or more of avariety of fuels (e.g., gasoline, diesel, bio-diesel, ethanol, naturalgas, etc.) to output mechanical energy. However, in light of theadvances and improvements in battery/electric vehicle technologies,according to some embodiments, the primary power source may comprise oneor more battery modules 800 configured to store energy that issubsequently converted to mechanical energy to power the variouscomponents of the concrete mixer truck 10. In such embodiments, thebattery module 800 may comprise one or more battery assemblies 820 thatstore chemical energy (e.g., lithium ion batteries, lead acid batteries,nickel-cadmium batteries, etc.) and/or electrical energy (e.g.capacitors or supercapacitors).

Referring to FIGS. 5, 10, and 11, the power plant module 302 is shownaccording to an exemplary embodiment. The power plant module 302 iscoupled the chassis 20 and positioned near the longitudinal center ofthe concrete mixer truck 10 beneath the mixing drum 202. In the powerplant module 302, the first electromagnetic device 306 and the secondelectromagnetic device 308 are coupled to the transmission 304. Thefirst electromagnetic device 306 is positioned on a front side of thetransmission 304, and the second electromagnetic device 308 ispositioned on an opposite, rear side of the transmission 304.Accordingly, the transmission 304 extends directly between the firstelectromagnetic device 306 and the second electromagnetic device 308.The first electromagnetic device 306 and the second electromagneticdevice 308 are coupled to the transmission 304 such that rotationalmechanical energy can be transferred between the first electromagneticdevice 306 and the transmission 304 and between the secondelectromagnetic device 308 and the transmission 304.

The power plant module 302 includes three rotational mechanical energyinputs and/or outputs (e.g., shafts, joints, couplers, receptacles,etc.), shown as front drive output 310, rear drive output 312, and PTOoutput 314. The front drive output 310, the rear drive output 312, andthe PTO output 314 transfer rotational mechanical energy from the powerplant module 302 to other systems of the concrete mixer truck 10. Thefront drive output 310, the rear drive output 312, and the PTO output314 may additionally or alternatively be configured to transferrotational mechanical energy from outside of the power plant module 302into the power plant module 302 (e.g., to perform regenerative braking,etc.). As shown in FIG. 10, the PTO output 314 is radially aligned(i.e., concentric) with the first electromagnetic device 306 and thesecond electromagnetic device 308. The front drive output 310 and therear drive output 312 are radially aligned with one another and radiallyoffset below the PTO output 314.

The first electromagnetic device 306 and the second electromagneticdevice 308 are configured to receive electrical energy (e.g., from thebattery module 800) and provide rotational mechanical energy to thetransmission 304. According to the embodiment shown in FIG. 10, thefirst electromagnetic device 306 and the second electromagnetic device308 operate using alternating current. In other embodiments, one or bothof the first electromagnetic device 306 and the second electromagneticdevice 308 operate using direct current. The first electromagneticdevice 306 and the second electromagnetic device 308 can each beconfigured to provide rotational mechanical energy separately, or bothelectromagnetic devices can provide rotational mechanical energysimultaneously. The first electromagnetic device 306 the secondelectromagnetic device 308 may have variable speeds and/or torques tofacilitate varying the output speeds and/or torques of the front driveoutput 310, the rear drive output 312, and the PTO output 314.

The first electromagnetic device 306 and the second electromagneticdevice 308 may additionally be configured to receive a mechanical energyoutput from the transmission 304 (e.g., when the concrete mixer truck 10is traveling downhill and/or braking) and provide an electrical energyoutput. By way of example, at least one of the first electromagneticdevice 306 and the second electromagnetic device 308 may be configuredto receive rotational mechanical energy from the transmission 304 andprovide an electrical energy output (i.e., at least one of the firstelectromagnetic device 306 and the second electromagnetic device 308 mayoperate as a generator, etc.). The operational condition of the firstelectromagnetic device 306 and the second electromagnetic device 308(e.g., as a motor, as a generator, etc.) may vary based on a mode ofoperation associated with the transmission 304 and/or based on anoperating condition of the concrete mixer truck 10 (e.g., a loadedweight of the concrete mixer truck 10, grade that the concrete mixertruck 10 is climbing, a load on the accessory module 600, etc.).

The transmission 304 is configured to transfer the rotational mechanicalenergy from the first electromagnetic device 306 and the secondelectromagnetic device 308 to the front drive output 310, the rear driveoutput 312, and the PTO output 314. The transmission 304 can includegears (e.g., planetary gear sets, spur gear sets, etc.), clutches,brakes, and other power transmission devices. The transmission 304 maybe configured to vary the output speed, output torque, and rotationdirection of the front drive output 310, the rear drive output 312, andthe PTO output 314 (e.g., by engaging one or more clutches or brakes,etc.). By way of example, the transmission 304 may be selectivelyreconfigurable between low speed, medium or mid speed, and high speedconfigurations. By way of another example, the transmission 304 may beconfigured to selectively vary a rotation direction of one or more ofthe outputs (e.g., entering a reverse configuration). The transmission304 may be configured to selectively decouple one or more of the frontdrive output 310, the rear drive output 312, and the PTO output 314 fromthe first electromagnetic device 306 and the second electromagneticdevice 308. By way of example, the transmission 304 may be configured todrive the PTO output 314 without operating the front drive output 310 orthe rear drive output 312.

The front drive output 310 is coupled to a first drive shaft, shown asfront drive shaft 510 (e.g., through a universal joint or constantvelocity joint). As shown in FIG. 10, the front drive shaft 510 includesone single segment. In other embodiments, the front drive shaft 510includes two or more segments. The front drive shaft 510 is coupled to apower transfer device of the front axle assembly 500, shown as frontdifferential 512. The front differential 512 is coupled to the wheel andtire assemblies 508 of the front axle assembly 500 through a pair ofhalf shafts. In operation, rotational mechanical energy from the frontdrive output 310 is transferred through the front drive shaft 510, thefront differential 512, and the half shafts to the wheel and tireassemblies 508 of the front axle assembly 500, and the wheel and tireassemblies 508 propel the concrete mixer truck 10.

The rear drive output 312 is coupled to a second drive shaft, shown asrear drive shaft 520 (e.g., through a universal joint or a constantvelocity joint). As shown in FIG. 10, the rear drive shaft 520 includesone single segment. In other embodiments, the rear drive shaft 520includes two or more segments. The rear drive shaft 520 is coupled to apower transfer device of the front most rear axle assembly 502, shown asrear differential 522. The rear differential 522 is coupled to the wheeland tire assemblies 508 of the front most rear axle assembly 502 througha pair of half shafts. A third drive shaft, shown as rear drive shaft524, is coupled to the rear differential 522. As shown in FIG. 5, therear drive shaft 524 includes one single segment. In other embodiments,the rear drive shaft 524 includes two or more segments. The rear driveshaft 524 is coupled to a power transfer device of the rearmost rearaxle assembly 502, shown as rear differential 526. The rear differential526 is coupled to the wheel and tire assemblies 508 of the rearmost rearaxle assembly 502 through a pair of half shafts. In operation,rotational mechanical energy from the rear drive output 312 istransferred through the rear drive shaft 520, the rear differential 522,and the half shafts to the wheel and tire assemblies 508 of the frontmost rear axle assembly 502, and rotational mechanical energy from therear differential 522 is transferred through the rear drive shaft 524,the rear differential 526, and the half shafts to the wheel and tireassemblies 508 of the rearmost rear axle assembly 502. The wheel andtire assemblies 508 then propel the concrete mixer truck 10.

The pusher axle assembly 504 and the tag axle assembly 506 are eachconfigured to be raised and lowered to selectively engage a supportsurface (e.g., the ground, etc.), redistributing the loads imparted onthe axle assemblies by the weight of the concrete mixer truck 10. Asshown in FIG. 5, the pusher axle assembly 504 and the tag axle assembly506 each include a set of actuators, shown as airbags 530. The airbags530 are coupled to and extend between the chassis 20 and thecorresponding pusher axle assembly 504 or tag axle assembly 506. Theairbags 530 are configured to receive or release compressed gas (e.g.,air, etc.) to extend or retract. When the airbags 530 are filled withgas, the airbags 530 expand, forcing the pusher axle assembly 504 and/orthe tag axle assembly 506 downward against the ground. This force causesthe pusher axle assembly 504 and/or the tag axle assembly 506 to liftthe chassis 20 and the components supported by the chassis 20, lesseningthe load on the front axle assembly 500 and/or the rear axle assembly502. Such a configuration reduces the pressure exerted on the ground bythe concrete mixer truck 10 and may be required when traveling throughcertain municipalities under load. When the gas is removed from theairbags 530, the pusher axle assembly 504 and the tag axle assembly 506are lifted off of contact with the ground, and the front axle assembly500 and the rear axle assembly 502 experience higher loading. Theairbags 530 may be configured such that the pusher axle assembly 504 andthe tag axle assembly 506 can be raised and lowered independently ortogether. By way of example, the pusher axle assembly 504 may be loweredwhen the mixing drum 202 is loaded to support the weight of the materialwithin the mixing drum 202. By way of another example, the tag axleassembly 506 can be lowered to support the weight of the battery module800.

The front axle assembly 500, the rear axle assemblies 502, the pusheraxle assembly 504, and the tag axle assembly 506 can include varioussuspension components (e.g., shock absorbers, sway bars, control arms,etc.), steering components, braking components, or power transmissioncomponents. As shown in FIG. 1, the front axle assembly 500, the rearaxle assemblies 502, the pusher axle assembly 504, and the tag axleassembly 506 all include braking components or brake assemblies, shownas brakes 532. The brakes 532 are coupled to each wheel and tireassembly 508 and configured to impart a braking force on thecorresponding wheel and tire assemblies 508. This braking force opposesrotation of the wheel and tire assemblies 508, reducing the speed of theconcrete mixer truck 10 and/or preventing the concrete mixer truck 10from moving. In one embodiment, the brakes 532 are air brakes that areconfigured to impart a braking force in response to receiving compressedgas (e.g., air, etc.). In other embodiments, one or more of the frontaxle assembly 500, the rear axle assemblies 502, the pusher axleassembly 504, and the tag axle assembly 506 do not include the brakes532.

In other embodiments, the concrete mixer truck 10 includes other axleconfigurations. In some embodiments, one or more of the pusher axleassembly 504 and the tag axle assembly 506 are omitted. Additionalpusher axle assemblies 504 or tag axle assemblies 506 can be included.In some embodiments, one of the rear axle assemblies 502 are omittedsuch that the concrete mixer truck 10 has a single rear axle instead ofa tandem rear axle. One or more of the front axle assembly 500 and therear axle assemblies 502 may be unpowered.

Referring to FIGS. 1 and 5, the longitudinal positions of the componentsof the concrete mixer truck 10 are shown relative to the center of thefront axle assembly 500. The front most point of the concrete mixertruck 10, which is defined by the railing 292, is offset a distance D₁forward from the center of the front axle assembly 500. The front 22 ofthe chassis 20 is offset a distance D₂ forward from the center of thefront axle assembly 500. Distance D₁ is greater than distance D₂.

The center of gravity of the cab 100 is offset a distance D₃ rearwardfrom the center of the front axle assembly 500. The center of gravity ofthe water tank 230 is offset a distance D₄ rearward from the center ofthe front axle assembly 500. The center of gravity of the of the powerplant module 302 is offset a distance D₅ rearward from the center of thefront axle assembly 500. The center of gravity of the power plant module302 may be located in the transmission 304, approximately centeredbetween the first electromagnetic device 306 and the secondelectromagnetic device 308. The center of gravity of the mixing drum 202is offset a distance D₆ rearward from the center of the front axleassembly 500. The center of gravity shown in FIG. 1 is the location ofthe center of gravity of the mixing drum 202 when the mixing drum 202 isempty. The location of the center of gravity of the mixing drum 202filled with material (e.g., concrete) may be offset (e.g., rearward)from the position shown, depending on the density and volume of materialwithin the mixing drum 202.

The center of the pusher axle assembly 504 is offset a distance D₇rearward from the center of the front axle assembly 500. The center ofthe front most rear axle assembly 502 is offset a distance D₈ rearwardfrom the center of the front axle assembly 500. The center of gravity ofthe accessory module 600 is offset a distance D₉ rearward from thecenter of the front axle assembly 500. As shown in FIGS. 5, 14, and 15,the accessory module 600 is positioned directly beneath and atapproximately the same longitudinal position as the rear pedestal 212and the drum driver 214. The center of the rear most rear axle assembly502 is offset a distance D₁₀ rearward from the center of the front axleassembly 500. The center of the tag axle assembly 506 is offset adistance D₁₁ rearward from the center of the front axle assembly 500.The center of gravity of the battery module 800 is offset a distance D₁₂rearward from the center of the front axle assembly 500. The rear mostpoint of the concrete mixer truck 10, which is defined by the rear end24 of the chassis 20, is offset a distance D₁₃ rearward from the centerof the front axle assembly 500. The distances D₃-D₁₃ are arranged inorder of increasing length such that D₃ is smaller than D₄, which issmaller than D₅, etc.

The centers of gravity of the cab 100, the power plant module 302, andthe mixing drum 202 (e.g., both when full and empty) are positionedforward of the rear axle assemblies 502, and the center of gravity ofthe battery module 800 is positioned rearward of the rear axleassemblies 502. Specifically, the centers of gravity of the cab 100, thepower plant module 302, and the mixing drum 202 are positioned forward apoint PRT centered between the rear axle assemblies 502, and the centerof gravity of the battery module 800 is positioned rearward of the pointPRT. Accordingly, the moments of the weights of the cab 100, the powerplant module 302, and the mixing drum 202 about the point PRT oppose themoments of the weight of the battery module 800 about the point PRT.This ensures that the weight of the concrete mixer truck 10 and itspayload is substantially evenly distributed between the axle assemblies.This also ensures that the front axle assembly 500 is not lifted awayfrom the ground due to the moment effect of the weight of the batterymodule 800 about the point PRT, which may otherwise make the concretemixer truck 10 more difficult to steer.

Referring to FIG. 12 the drive system 300 includes the transmission 304,the first electromagnetic device 306, the second electromagnetic device308, a first drive shaft, shown as front drive shaft 510, a second driveshaft, shown as rear drive shaft 520, and the PTO shaft 602. Thetransmission 304 is configured to transfer the rotational mechanicalenergy between the first electromagnetic device 306 and the secondelectromagnetic device 308 and the front drive shaft 510, the rear driveshaft 520, and the PTO shaft 602. According to the exemplary embodimentshown in FIG. 12, the transmission 304 includes a first gear set orpower transmission device, shown as power split planetary 410, and asecond gear set or power transmission device, shown as output planetary420. In one embodiment, the power split planetary 410 and the outputplanetary 420 are disposed between the first electromagnetic device 306and the second electromagnetic device 308. In an alternative embodiment,one or both of the power split planetary 410 and the output planetary420 are positioned outside of (i.e., not between, etc.) the firstelectromagnetic device 306 and the second electromagnetic device 308.

Referring to the exemplary embodiment shown in FIG. 12, the power splitplanetary 410 is a planetary gear set that includes a first rotatableportion, shown as sun gear 412, a second rotatable portion, shown asring gear 414, and a plurality of connecting members, shown as planetarygears 416. The plurality of the planetary gears 416 couple the sun gear412 to the ring gear 414, according to an exemplary embodiment. As shownin FIG. 12, a carrier 418 rotationally supports the plurality of theplanetary gears 416. In one embodiment, the first electromagnetic device306 is directly coupled to the sun gear 412 such that the power splitplanetary 410 is coupled to the first electromagnetic device 306. By wayof example, the first electromagnetic device 306 may include a shaft(e.g., a first shaft, an input shaft, an output shaft, etc.) directlycoupled to the sun gear 412.

Referring still to the exemplary embodiment shown in FIG. 12, the outputplanetary 420 is a planetary gear set that includes a first rotatableportion, shown as sun gear 422, a second rotatable portion, shown asring gear 424, and a plurality of connecting members, shown as planetarygears 426. The plurality of planetary gears 426 couple the sun gear 422to the ring gear 424, according to an exemplary embodiment. As shown inFIG. 12, a carrier 428 rotationally supports the plurality of planetarygears 426. In one embodiment, the second electromagnetic device 308 isdirectly coupled to the sun gear 422 such that the output planetary 420is coupled to the second electromagnetic device 308. By way of example,the second electromagnetic device 308 may include a shaft (e.g., asecond shaft, an input shaft, an output shaft, etc.) directly coupled tothe sun gear 422. The carrier 418 is directly coupled to the carrier428, thereby coupling the power split planetary 410 to the outputplanetary 420, according to the exemplary embodiment shown in FIG. 12.In one embodiment, directly coupling the carrier 418 to the carrier 428synchronizes the rotational speeds of the carrier 418 and the carrier428.

According to an exemplary embodiment, the transmission 304 includes afirst clutch, shown as power split coupled clutch 430. In oneembodiment, the power split coupled clutch 430 is positioned downstreamof the power split planetary 410 (e.g., between the power splitplanetary 410 and the front drive shaft 510 or the rear drive shaft 520,etc.). As shown in FIG. 12, the power split coupled clutch 430 ispositioned to selectively couple the power split planetary 410 and theoutput planetary 420 with a shaft, shown as output shaft 332.Specifically, the power split coupled clutch 430 is positioned toselectively couple the carrier 418 and the carrier 428 with the outputshaft 332. In one embodiment, the power split coupled clutch 430 allowsthe concrete mixer truck 10 to be towed without spinning the componentswithin the transmission 304 (e.g., the power split planetary 410, theoutput planetary 420, etc.). The output shaft 332 may be coupled to therear drive shaft 520 and selectively coupled to front drive shaft 510with a declutch assembly, shown as front de-couple collar shift 334. Thefront de-couple collar shift 334 may be engaged and disengaged toselectively couple the front drive shaft 510 to the output shaft 332 ofthe transmission 304 (e.g., to facilitate operation of the concretemixer truck 10 in a rear-wheel-drive-only mode, an all-wheel-drive mode,a six-wheel-drive mode, etc.).

As shown in FIG. 12, the transmission 304 includes a second clutch,shown as PTO clutch 440. The PTO clutch 440 is positioned to selectivelycouple the second electromagnetic device 308 with the accessory module600 through the PTO shaft 602, according to an exemplary embodiment. ThePTO clutch 440 may thereby selectively couple the accessory module 600and the PTO shaft 602 to the output planetary 420. As shown in FIG. 12,the transmission 304 includes a shaft, shown as connecting shaft 336,coupled to the PTO shaft 602. According to an exemplary embodiment, theconnecting shaft 336 extends from the PTO shaft 602, through the secondelectromagnetic device 308, and through the output planetary 420 to thepower split planetary 410. The connecting shaft 336 couples the PTOshaft 602 with the power split planetary 410, according to the exemplaryembodiment shown in FIG. 9. In one embodiment, the connecting shaft 336directly couples the PTO shaft 602 with the ring gear 414 of the powersplit planetary 410. The PTO clutch 440 may selectively couple thesecond electromagnetic device 308 with the connecting shaft 336.According to an exemplary embodiment, the shaft (e.g., input/outputshaft, etc.) of the first electromagnetic device 306 and the shaft(e.g., input/output shaft, etc.) of the second electromagnetic device308 are radially aligned with the power split planetary 410, the outputplanetary 420, and the connecting shaft 336 (e.g., centerlines thereofare aligned, etc.). One end of the PTO shaft 602 (e.g., a universaljoint or constant velocity joint of the PTO shaft 602) may be radiallyaligned with the connecting shaft 336. The PTO shaft 602 may not bealigned with the connecting shaft 336 as the PTO shaft 602 extends awayfrom the transmission 304 (e.g., may extend at an angle relative to theconnecting shaft 336). As shown in FIG. 12, the transmission 304includes a third clutch, shown as output coupled clutch 450. The outputcoupled clutch 450 is positioned to selectively couple the outputplanetary 420 with the output shaft 332, according to an exemplaryembodiment. In on embodiment, the output coupled clutch 450 ispositioned to selectively couple the ring gear 424 with the output shaft332. In one embodiment, the output shaft 332 is radially offset from thepower split planetary 410, the output planetary 420, and the connectingshaft 336 (e.g., radially offset from centerlines thereof, etc.).

Referring again to the exemplary embodiment shown in FIG. 12, thetransmission 304 includes a brake, shown as output brake 470. The outputbrake 470 is positioned to selectively inhibit the movement of at leasta portion of the output planetary 420 (e.g., the ring gear 424, etc.),according to an exemplary embodiment. In one embodiment, the outputbrake 470 is biased into an engaged position (e.g., with a spring, etc.)and selectively disengaged (e.g., with application of pressurizedhydraulic fluid, etc.). In other embodiments, the output brake 470 ishydraulically-biased and spring released. In still other embodiments,the components of the transmission 304 are still otherwise engaged anddisengaged (e.g., pneumatically, etc.). By way of example, the outputbrake 470 and the output coupled clutch 450 may be engagedsimultaneously to function as a driveline brake (e.g., a brakingmechanism to slow down the concrete mixer truck 10, etc.).

As shown in FIG. 12, the transmission 304 includes a gear set 480 thatcouples the carrier 418 and the carrier 428 to the output shaft 332. Inone embodiment, the gear set 480 includes a first gear, shown as gear482, in meshing engagement with a second gear, shown as gear 484. Asshown in FIG. 12, the gear 482 is rotatably coupled to the carrier 418and the carrier 428. By way of example, the gear 482 may be fixed to acomponent (e.g., shaft, tube, etc.) that couples the carrier 418 and thecarrier 428. As shown in FIG. 12, the power split coupled clutch 430 ispositioned to selectively couple the gear 484 with the output shaft 332when engaged. With the power split coupled clutch 430 disengaged,relative movement (e.g., rotation, etc.) may occur between the gear 484and the output shaft 332.

According to an exemplary embodiment, the transmission 304 includes agear set, shown as gear set 490 that couples the output planetary 420 tothe output shaft 332. As shown in FIG. 12, the gear set 490 includes afirst gear, shown as gear 492, coupled to the ring gear 424 of theoutput planetary 420. The gear 492 is in meshing engagement with asecond gear, shown as gear 494, according to an exemplary embodiment. Asshown in FIG. 12, the gear 494 is coupled to a third gear, shown as gear496. In other embodiments, the gear 492 is directly coupled with thegear 496. By way of example, the gear set 490 may not include the gear494, and the gear 492 may be directly coupled to (e.g., in meshingengagement with, etc.) the gear 496. As shown in FIG. 12, the outputcoupled clutch 450 is positioned to selectively couple the gear 496 withthe output shaft 332 when engaged. With the output coupled clutch 450disengaged, relative movement (e.g., rotation, etc.) may occur betweenthe gear 496 and the output shaft 332. By way of example, the outputcoupled clutch 450 may be engaged to couple the ring gear 424 to theoutput shaft 332. The output brake 470 is positioned to selectivelylimit the movement of the gear 492 when engaged to thereby also limitthe movement of the ring gear 424, the gear 494, and the gear 496.

Tractive Assemblies

Referring to FIGS. 10-12, the front de-couple collar shift 334 iscoupled to the front drive shaft 510 (e.g., through a universal joint orconstant velocity joint). Accordingly, the front drive shaft 510 iscoupled to the output shaft 332 through the front de-couple collar shift334. As shown in FIG. 10, the front drive shaft 510 includes one singlesegment. In other embodiments, the front drive shaft 510 includes two ormore segments. The front drive shaft 510 is coupled to a power transferdevice of the front axle assembly 500, shown as front differential 512.The front differential 512 is coupled to the wheel and tire assemblies508 of the front axle assembly 500 through a pair of half shafts. Inoperation, rotational mechanical energy from the output shaft 332 istransferred through the front de-couple collar shift 334, the frontdrive shaft 510, the front differential 512, and the half shafts to thewheel and tire assemblies 508 of the front axle assembly 500, and thewheel and tire assemblies 508 propel the concrete mixer truck 10.

The output shaft 332 is coupled to the rear drive shaft 520 (e.g.,through a universal joint or a constant velocity joint). As shown inFIG. 10, the rear drive shaft 520 includes one single segment. In otherembodiments, the rear drive shaft 520 includes two or more segments. Therear drive shaft 520 is coupled to a power transfer device of the frontmost rear axle assembly 502, shown as rear differential 522. The reardifferential 522 is coupled to the wheel and tire assemblies 508 of thefront most rear axle assembly 502 through a pair of half shafts. A thirddrive shaft, shown as rear drive shaft 524, is coupled to the reardifferential 522. As shown in FIG. 5, the rear drive shaft 524 includesone single segment. In other embodiments, the rear drive shaft 524includes two or more segments. The rear drive shaft 524 is coupled to apower transfer device of the rearmost rear axle assembly 502, shown asrear differential 526. The rear differential 526 is coupled to the wheeland tire assemblies 508 of the rearmost rear axle assembly 502 through apair of half shafts. In operation, rotational mechanical energy from theoutput shaft 332 is transferred through the rear drive shaft 520, therear differential 522, and the half shafts to the wheel and tireassemblies 508 of the front most rear axle assembly 502, and rotationalmechanical energy from the rear differential 522 is transferred throughthe rear drive shaft 524, the rear differential 526, and the half shaftsto the wheel and tire assemblies 508 of the rearmost rear axle assembly502. The wheel and tire assemblies 508 then propel the concrete mixertruck 10.

The pusher axle assembly 504 and the tag axle assembly 506 are eachconfigured to be raised and lowered to selectively engage a supportsurface (e.g., the ground, etc.), redistributing the loads imparted onthe axle assemblies by the weight of the concrete mixer truck 10. Asshown in FIG. 5, the pusher axle assembly 504 and the tag axle assembly506 each include a set of actuators, shown as airbags 530. The airbags530 are coupled to and extend between the chassis 20 and thecorresponding pusher axle assembly 504 or tag axle assembly 506. Theairbags 530 are configured to receive or release compressed gas (e.g.,air, etc.) to extend or retract. When the airbags 530 are filled withgas, the airbags 530 expand, forcing the pusher axle assembly 504 and/orthe tag axle assembly 506 downward against the ground. This force causesthe pusher axle assembly 504 and/or the tag axle assembly 506 to liftthe chassis 20 and the components supported by the chassis 20, lesseningthe load on the front axle assembly 500 and/or the rear axle assembly502. Such a configuration reduces the pressure exerted on the ground bythe concrete mixer truck 10 and may be required when traveling throughcertain municipalities under load. When the gas is removed from theairbags 530, the pusher axle assembly 504 and the tag axle assembly 506are lifted off of contact with the ground, and the front axle assembly500 and the rear axle assembly 502 experience higher loading. Theairbags 530 may be configured such that the pusher axle assembly 504 andthe tag axle assembly 506 can be raised and lowered independently ortogether. By way of example, the pusher axle assembly 504 may be loweredwhen the mixing drum 202 is loaded to support the weight of the materialwithin the mixing drum 202. By way of another example, the tag axleassembly 506 can be lowered to support the weight of the battery module800.

The front axle assembly 500, the rear axle assemblies 502, the pusheraxle assembly 504, and the tag axle assembly 506 can include varioussuspension components (e.g., shock absorbers, sway bars, control arms,etc.), steering components, braking components, or power transmissioncomponents. As shown in FIG. 1, the front axle assembly 500, the rearaxle assemblies 502, the pusher axle assembly 504, and the tag axleassembly 506 all include braking components or brake assemblies, shownas brakes 532. The brakes 532 are coupled to each wheel and tireassembly 508 and configured to impart a braking force on thecorresponding wheel and tire assemblies 508. This braking force opposesrotation of the wheel and tire assemblies 508, reducing the speed of theconcrete mixer truck 10 and/or preventing the concrete mixer truck 10from moving. In one embodiment, the brakes 532 are air brakes that areconfigured to impart a braking force in response to receiving compressedgas (e.g., air, etc.). In other embodiments, one or more of the frontaxle assembly 500, the rear axle assemblies 502, the pusher axleassembly 504, and the tag axle assembly 506 do not include the brakes532.

In other embodiments, the concrete mixer truck 10 includes other axleconfigurations. In some embodiments, one or more of the pusher axleassembly 504 and the tag axle assembly 506 are omitted. Additionalpusher axle assemblies 504 or tag axle assemblies 506 can be included.In some embodiments, one of the rear axle assemblies 502 are omittedsuch that the concrete mixer truck 10 has a single rear axle instead ofa tandem rear axle. One or more of the front axle assembly 500 and therear axle assemblies 502 may be unpowered.

Accessory Module

As shown in FIGS. 10 and 11, the PTO shaft 602 is coupled to the PTOoutput 314 and the accessory module 600 (e.g., through a universal jointor a constant velocity joint). The PTO shaft 602 is configured totransfer rotational mechanical energy from the PTO output 314 to theaccessory module 600. In the embodiment shown in FIG. 10, the PTO shaft602 includes two segments coupled to one another. In other embodiments,the PTO shaft 602 includes more or fewer segments.

Referring to FIGS. 13-16, the accessory module 600 is shown according toan exemplary embodiment. The accessory module 600 includes a frame 610that supports the various components of the accessory module 600. Theframe 610 is coupled to the chassis 20 through a series of isolatingmounts, shown as isolators 612. The isolators 612 are made of acomplaint material, such as rubber, and configured to reduce thetransfer of vibrations between the accessory module 600 and the chassis20. The frame 610 is formed from multiple pieces of bent sheet metal. Inother embodiments, the frame 610 is otherwise formed (e.g., includingone or more tubular frame members, etc.). As shown in FIG. 13, the frame610 includes an interface, shown as lift eye 614, having an apertureextending therethrough. The lift eye 614 facilitates lifting theaccessory module 600 such that the entire accessory module 600 can bemanipulated as a subassembly for assembly and/or maintenance.

The accessory module 600 includes a series of power transfer devicesconfigured to convert rotational mechanical energy from the PTO output314 to other forms (e.g., electricity, a flow of pressurized workingfluid, etc.). The accessory module 600 includes a first hydraulic pump,shown as drum drive pump 620, and a second hydraulic pump, shown asaccessory pump 622. One or both of the drum drive pump 620 and theaccessory pump 622 may be fluidly coupled to the hydraulic fluid tank606 and configured to receive a working fluid, specifically hydraulicfluid, at a low pressure (e.g., atmospheric pressure) from the hydraulicfluid tank 606. The drum drive pump 620 and the accessory pump 622 areconfigured to receive rotational mechanical energy and output a flow ofpressurized hydraulic fluid to drive other functions. The concrete mixertruck 10 may include other hydraulic components (e.g., valves, filters,pipes, hoses, etc.) that facilitate operation and control of a hydrauliccircuit including the drum drive pump 620 and/or the accessory pump 622.By way of example, the concrete mixer truck 10 may include directionalcontrol valves that are controlled by a controller of the concrete mixertruck 10 (e.g., in response to an operator input through the userinterface 102, automatically in response to sensor inputs, etc.).

The drum drive pump 620 is fluidly coupled to the drum drive motor 252such that the drum drive pump 620 provides a flow of pressurizedhydraulic fluid to power the drum driver 214. In one embodiment, thedrum drive pump 620 powers only the drum driver 214. In someembodiments, the drum drive pump 620 is a variable displacement pumpconfigured to selectively vary the flow rate of hydraulic fluid that itprovides for a given rotational mechanical energy input. Thisfacilitates control over the speed of the mixing drum 202 with minimalenergy losses. In other embodiments, the drum drive pump 620 is a fixeddisplacement pump. Additionally or alternatively, the drum drive motor252 may be a variable displacement motor.

The accessory pump 622 is fluidly coupled to the other hydraulicactuators of the concrete mixer truck 10 such that the accessory pump622 provides pressurized hydraulic fluid to power the hydraulicactuators. By way of example, the accessory pump 622 may providepressurized hydraulic fluid to power the hopper actuator 260, the chuteheight actuator 280, the chute rotation actuator 282, and the chutefolding actuators 284. The accessory pump 622 may be a variabledisplacement pump or a fixed displacement pump. In an alternativeembodiment, the drum drive pump 620 and the accessory pump 622 arereplaced with a single hydraulic pump that supplies pressurizedhydraulic fluid to all of the hydraulic actuators of the concrete mixertruck 10 (e.g., the drum drive motor 252, the hopper actuator 260, thechute height actuator 280, the chute rotation actuator 282, and thechute folding actuators 284).

The accessory module 600 further includes a first compressor, shown asdrivetrain compressor 630. The drivetrain compressor 630 is configuredto receive rotational mechanical energy and a working fluid,specifically gas, at a low pressure and provide compressed gas at a highpressure to drive other functions of the concrete mixer truck 10. Insome embodiments, the drivetrain compressor 630 is configured tocompress air. In such an embodiment, the drivetrain compressor 630 isconfigured to receive air at atmospheric pressure from the surroundingatmosphere and output compressed air at greater than atmosphericpressure. The drivetrain compressor 630 is fluidly coupled to the airtank 604 such that the compressed gas from the drivetrain compressor 630is stored within the air tank 604 prior to use. The concrete mixer truck10 may include other pneumatic components (e.g., valves, filters, pipes,hoses, etc.) that facilitate operation and control of a pneumaticcircuit including the drivetrain compressor 630. By way of example, theconcrete mixer truck 10 may include pneumatic solenoids that arecontrolled by a controller of the concrete mixer truck 10 (e.g., inresponse to an operator input through the user interface 102,automatically in response to sensor inputs, etc.). The drivetraincompressor 630 is fluidly coupled to the airbags 530 and the brakes 532such that the drivetrain compressor 630 provides compressed air toexpand the airbags 530 and activate the brakes 532.

The accessory module 600 further includes a second compressor, shown asair conditioning compressor 632. The air conditioning compressor 632 isconfigured to receive rotational mechanical energy and a working fluid,specifically gas, at a low pressure and provide compressed gas at a highpressure. Specifically, the air conditioning compressor 632 isconfigured to compress a refrigerant (e.g., R-134a, etc.) for use in aclimate control or air conditioning system of the concrete mixer truck10. The air conditioning compressor 632 may be part of an airconditioning circuit including a first heat transfer device or radiatoracting as a condenser, an expansion valve, and a second heat transferdevice or radiator acting as an evaporator. The air conditioningcompressor 632 is configured to receive refrigerant at a low pressurefrom the evaporator and supply high pressure refrigerant to thecondenser. The evaporator may be in fluid communication with the cab 100such that the air conditioning system provides cooled air to the cab 100to improve operator comfort. The concrete mixer truck 10 may includeother components (e.g., valves, hoses, switches, fans, etc.) thatfacilitate operation and control of the air conditioning system. Inother embodiments, the concrete mixer truck 10 does not include an airconditioning system for the cab 100, and the air conditioning compressor632 is omitted.

The accessory module 600 further includes an electrical machine,electromagnetic device, and/or generator, shown as alternator 640. Thealternator 640 is configured to receive a rotational mechanical energyinput and provide electrical energy. In some embodiments, the alternator640 is configured to provide direct current electrical energy. Thealternator 640 is electrically coupled to an energy storage device,shown in FIG. 49, described in detail below, as battery 642, configuredto store the electrical energy from the alternator 640. In oneembodiment, the battery 642 is a 12 volt battery. The electrical energyfrom the alternator 640 and the battery 642 is used to power one or morefunctions of the concrete mixer truck 10. By way of example, the battery642 may be configured to provide electrical energy to power the userinterface 102, one or more lights of the concrete mixer truck 10, or acontroller of the concrete mixer truck. In some embodiments, thealternator 640 and the battery 642 are electrically decoupled from thebattery module 800 such that the alternator 640 and the battery module800 each provide electrical energy to different components. In otherembodiments, the alternator 640 and the battery 642 are omitted, and thebattery module 800 provides electrical energy to the components thatwould have otherwise been powered by the alternator 640.

Referring to FIGS. 13, 14, and 17, the drum drive pump 620, theaccessory pump 622, the drivetrain compressor 630, the air conditioningcompressor 632, and the alternator 640 are coupled (e.g., directly orindirectly) to the PTO shaft 602 and configured to receive rotationalmechanical energy from the PTO shaft 602. The drum drive pump 620 isdirectly coupled to the PTO shaft 602 and configured to receiverotational mechanical energy directly from the PTO shaft 602. Theaccessory pump 622 is coupled to the drum drive pump 620, and the drumdrive pump 620 is configured to transfer a portion of the rotationalmechanical energy received from the PTO shaft 602 to the accessory pump622. In one embodiment, one shaft coupled to the PTO shaft 602 extendsthrough both the drum drive pump 620 and the accessory pump 622 totransfer rotational mechanical energy.

The drivetrain compressor 630, the air conditioning compressor 632, andthe alternator 640 are each radially offset from the PTO shaft 602. Theaccessory module 600 further includes a power transfer device, shown asserpentine belt assembly 650, which is configured to transfer rotationalmechanical energy from the PTO shaft 602 to the drivetrain compressor630, the air conditioning compressor 632, and the alternator 640. Theserpentine belt assembly 650 includes a first pulley, shown as PTOpulley 652, directly coupled to the PTO shaft 602. A second pulley,shown as drivetrain compressor pulley 654, is coupled to the drivetraincompressor 630. A third pulley, shown as air conditioning compressorpulley 656, is coupled to the air conditioning compressor 632. A fourthpulley, shown as alternator pulley 658, is coupled to the alternator640. A power transfer band, shown as serpentine belt 660, extendsbetween the pulleys, transferring rotational mechanical energy from thePTO shaft 602 to the drivetrain compressor 630, the air conditioningcompressor 632, and the alternator 640.

The serpentine belt assembly 650 further includes a pair of idlerpulleys, shown as idler pulley 662 and idler pulley 664. The idlerpulley 662 is rotatably coupled to the frame 610. The idler pulley 664is rotatably coupled to a mount or linkage, shown as tensioning link666. The tensioning link 666 is rotatably coupled to the frame 610. Theserpentine belt 660 forms a closed loop, extending between the PTOpulley 652, the idler pulley 662, the drivetrain compressor pulley 654,the air conditioning compressor pulley 656, the alternator pulley 658,and the idler pulley 664, respectively. The serpentine belt 660 couplesthe pulleys such that each of the pulleys rotate simultaneously inresponse to rotation of the PTO shaft 602. The idler pulley 662 and theidler pulley 664 direct the serpentine belt 660 such that more surfacearea of the serpentine belt 660 contacts the alternator pulley 658, thePTO pulley 652, and the drivetrain compressor pulley 654, facilitating asecure connection. The tensioning link 666 is biased (e.g., by a torsionspring, etc.) to rotate relative to the frame 610 (e.g., counterclockwise as shown in FIG. 16). This applies a biasing force on theidler pulley 664, which in turn tensions the serpentine belt 660,strengthening the connections between the serpentine belt 660 and thepulleys.

Power Plant Module Including Variators

Referring to FIG. 18, a drive system 1000 is shown as an alternativeembodiment to the drive system 300. The drive system 1000 issubstantially similar to the drive system 300 except the power splitplanetary 410 and the output planetary 420 are replaced with variableratio power transmission devices or planetary assemblies, shown as powersplit variator 1010 and output variator 1020, respectively. In otherembodiments, only one of the power split planetary 410 and the outputplanetary 420 are replaced. The power split variator 1010 and the outputvariator 1020 are each configured to vary a ratio (e.g., a torque ratio,a gear ratio, a speed ratio, etc.) between an input to the variator andan output from the variator. The power split variator 1010 and theoutput variator 1020 may have various arrangements (e.g., an epicyclicor planetary arrangement, a radially offset arrangement, etc.). Thepower split variator 1010 and the output variator 1020 may utilizevarious types of variator configurations. By way of example, the powersplit variator 1010 and the output variator 1020 may belt and/or chainvariators (e.g., include one or more belts or chains rotationallycoupling variable diameter pulleys, etc.). In such an example, varyingthe pulley diameters may adjust the relative speeds between variouscomponents within the power split variator 1010. Such a belt variatorand/or a chain variator may be a planetary device.

As shown in FIG. 18, the power split variator 1010 includes an innerportion 1011 and the output variator 1020 includes an inner portion1021. The inner portion 1011 and the inner portion 1021 are shownaccording to various exemplary embodiments in FIGS. 19 and 20. In FIGS.19 and 20, the power split variator 1010 and the output variator 1020are epicyclic or planetary devices. The power split variator 1010includes a first rotatable portion 1012, a second rotatable portion1014, and one or more adjustable members or connecting members 1016 eachconfigured to rotate about a corresponding the axis 1017. The connectingmembers 1016 engage (e.g., rotationally) both the first rotatableportion 1012 and the second rotatable portion 1014, thereby coupling thefirst rotatable portion 1012 to the second rotatable portion 1014,according to an exemplary embodiment. A carrier 1018 rotationallysupports the connecting members 1016 such that each connecting member1016 rotates relative to the carrier 1018 about the corresponding theaxis 1017. In some embodiments, the connecting members 1016 areselectively repositionable such that the axes 1017 rotate relative tothe carrier 1018. As the orientations of the connecting members 1016change relative to the carrier 1018, the connecting members 1016 mayengage the first rotatable portion 1012 and the second rotatable portion1014 at different locations, varying the speed ratios between the firstrotatable portion 1012, the second rotatable portion 1014, and thecarrier 1018.

The output variator 1020 includes a first rotatable portion 1022, asecond rotatable portion 1024, and one or more adjustable members orconnecting members 1026 each configured to rotate about a correspondingaxis 1027. The connecting members 1026 engage (e.g., rotationally) boththe first rotatable portion 1022 and the second rotatable portion 1024,thereby coupling the first rotatable portion 1022 to the secondrotatable portion 1024, according to an exemplary embodiment. A carrier1028 rotationally supports the connecting members 1026 such that eachconnecting member 1026 rotates relative to the carrier 1028 about thecorresponding axis 1027. In some embodiments, the connecting members1026 are selectively repositionable such that the axes 1027 rotaterelative to the carrier 1028. As the orientations of the connectingmembers 1026 change relative to the carrier 1028, the connecting members1026 may engage the first rotatable portion 1022 and the secondrotatable portion 1024 at different locations, varying the speed ratiosbetween the first rotatable portion 1022, the second rotatable portion1024, and the carrier 1028.

In the embodiment shown in FIG. 19, the power split variator 1010 andthe output variator 1020 are epicyclic or planetary devices configuredas friction ball variators. Although the power split variator 1010 isdescribed hereinafter, it should be understood that a similardescription applies to the corresponding components of the outputvariator 1020 (e.g., the connecting members 1016 corresponding to theconnecting members 1026, etc.). In this embodiment, the connectingmembers 1016 are balls (e.g., spheres, etc.) that are rotatable relativeto the carrier 1018 about the axes 1017. In the embodiment shown in FIG.19, the power split variator 1010 is shown to include two the connectingmembers 1016, however, the power split variator 1010 may include more orfewer connecting members 1016 (e.g., 1, 3, 4, 10, etc.). The firstrotatable portion 1012 and the second rotatable portion 1014 eachinclude an engagement surface that extends along a circular path and isconfigured to engage the connecting members 1016 (e.g., throughfriction, etc.). Accordingly, the first rotatable portion 1012 isrotationally engaged with the second rotatable portion 1014 through theconnecting members 1016. Each connecting member 1016 is configured torotate relative to the carrier 1018 about an axis 1017 in response to arotational mechanical energy input (e.g., through the first rotatableportion 1012, through the second rotatable portion 1014, through thecarrier 1018, etc.).

In some embodiments, the axes 1017 are fixed (e.g., permanently,selectively, etc.) relative to the carrier 1018. In other embodiments,to facilitate varying speed ratios between inputs to the power splitvariator 1010 and outputs from the power split variator 1010, each axis1017 is rotatable relative to the carrier 1018 (e.g., such that the axis1017 rotates about an axis extending perpendicular to the plane of FIG.19). The connecting members 1016 may have a curved profile such thatrotating the axes 1017 of the connecting members 1016 varies the ratiosbetween the speed of the first rotatable portion 1012, the speed of thesecond rotatable portion 1014, and the speed of the carrier 1018.Rotating the axis 1017 corresponding to one of the connecting members1016 in a first direction both (a) reduces the distance between that theaxis 1017 and the point where the first rotatable portion 1012 engagesthat connecting member 1016 and (b) increases the distance between thatthe axis 1017 and the point where the second rotatable portion 1014engages that connecting member 1016. In one such arrangement, with thecarrier 1018 held fixed, the first rotatable portion 1012 rotates moreslowly than the second rotatable portion 1014. Rotating the axis 1017 inthe opposite direction may have the opposite effect. In someembodiments, the axes 1017 are rotationally coupled such that theyrotate in unison.

In the embodiment shown in FIG. 20, the power split variator 1010 andthe output variator 1020 are epicyclic or planetary devices configuredas toroidal variators. Although the power split variator 1010 isdescribed hereinafter, it should be understood that a similardescription applies to the corresponding components of the outputvariator 1020 (e.g., the connecting members 1016 corresponding to theconnecting members 1026, etc.). In this embodiment, each connectingmember 1016 is a wheel or disc that is rotatable relative to the carrier1018. In the embodiment shown in FIG. 20, the power split variator 1010is shown to include two the connecting members 1016, however, the powersplit variator 1010 may include more or fewer the connecting members1016 (e.g., 1, 3, 4, 10, etc.). The first rotatable portion 1012 and thesecond rotatable portion 1014 each include a toroidal engagement surfacethat is configured to engage the connecting members 1016 (e.g., throughfriction, etc.). Accordingly, the first rotatable portion 1012 isrotationally engaged with the second rotatable portion 1014 through theconnecting members 1016. Each connecting member 1016 is configured torotate relative to the carrier 1018 about an axis 1017 in response to arotational mechanical energy input (e.g., through the first rotatableportion 1012, through the second rotatable portion 1014, through thecarrier 1018, etc.).

In some embodiments, the axes 1017 are fixed relative to the carrier1018. In other embodiments, to facilitate varying speed ratios betweeninputs to the power split variator 1010 and outputs from the power splitvariator 1010, each axis 1017 is rotatable relative to the carrier 1018(e.g., such that the axis 1017 rotates about an axis extendingperpendicular to the plane of FIG. 20). To facilitate continuousengagement between the connecting members 1016, the first rotatableportion 1012, and the second rotatable portion 1014 as the axis 1017rotates, the toroidal engagement surfaces may be concave with a constantradius cross sectional curvature. In such embodiments, rotating the axes1017 varies the ratios between the speed of the first rotatable portion1012, the speed of the second rotatable portion 1014, and the speed ofthe carrier 1018. Rotating the axis 1017 corresponding to one of theconnecting members 1016 in a first direction both (a) increases theradius between the axis of rotation of the first rotatable portion 1012and the point where that connecting member 1016 engages the firstrotatable portion 1012 and (b) decreases the radius between the axis ofrotation of the second rotatable portion 1014 and the point where thatconnecting member 1016 engages the second rotatable portion 1014. In onesuch arrangement, with the carrier 1018 held fixed, the first rotatableportion 1012 rotates more slowly than the second rotatable portion 1014.Rotating the axis 1017 in the opposite direction has the oppositeeffect. In some embodiments, the axes 1017 are rotationally coupled suchthat they rotate in unison.

As shown in FIG. 21, described in detail below, the power split variator1010 and the output variator 1020 each include an adjustment mechanismor actuator, shown as variator adjustment mechanism 1050. The variatoradjustment mechanisms 1050 are configured to rotate the axes 1017relative to the carrier 1018, rotate the axes 1027 relative to thecarrier 1028, or otherwise vary speed ratios of the power split variator1010 and the output variator 1020. The variator adjustment mechanism1050 may be a hydraulic actuator, a pneumatic actuator, an electricmotor, or another type of actuator that is controlled by anothercomponent (e.g., a controller). By way of example, a controller (e.g.,controller 910, described below with respect to FIG. 21) may control thevariator adjustment mechanism 1050 to control the speed of the outputshaft 332 and/or the PTO shaft 602. Alternatively, the variatoradjustment mechanism 1050 may be controlled passively (e.g., using aflyweight system). By way of example, the variator adjustment mechanism1050 may include a spring loaded flyweight coupled to a component of thepower split variator 1010 (e.g., the carrier 1018) such that thevariator adjustment mechanism 1050 varies the orientation of the axes1017 based on a rotational speed of the component. In other embodiments,the axes 1017 are fixed relative to the carrier 1018, and the variatoradjustment mechanism 1050 is omitted.

Control System

According to the exemplary embodiment shown in FIG. 21, a control system900 for the concrete mixer truck 10 includes a controller 910. In oneembodiment, the controller 910 is configured to selectively engage,selectively disengage, or otherwise communicate with components of theconcrete mixer truck 10 according to various modes of operation. Thecontroller 910 is coupled to the first electromagnetic device 306 andthe second electromagnetic device 308, according to an exemplaryembodiment, and may send and receive signals therewith. By way ofexample, the controller 910 may send command signals relating to atleast one of a target rotational speed, a target torque, and a targetrotation direction for the first electromagnetic device 306 and thesecond electromagnetic device 308. The controller 910 is coupled to thedrum driver 214, the hopper actuator 260, the chute height actuator 280,the chute rotation actuator 282, the chute folding actuators 284, theairbags 530, and the brakes 532, according to an exemplary embodiment,and may send and receive signals therewith (e.g., indirectly through oneor more valves).

As shown in FIG. 21, the first electromagnetic device 306 and the secondelectromagnetic device 308 are electrically coupled (e.g., through anelectrical connection provided by a bus). By way of example, powergenerated by the first electromagnetic device 306 (e.g., in response toa rotational input from the rear drive shaft 520 and/or the front driveshaft 510 through the transmission 304, etc.) may be utilized by thesecond electromagnetic device 308 (e.g., to provide an output torque asa motor, etc.), or power generated by the second electromagnetic device308 may be utilized by the first electromagnetic device 306 (e.g., toprovide an output torque as a motor, etc.). In other embodiments, thefirst electromagnetic device 306 and the second electromagnetic device308 are electrically decoupled from one another and/or the firstelectromagnetic device 306 and the second electromagnetic device 308 areselectively electrically coupled to one another (e.g., using a switch).The first electromagnetic device 306 and the second electromagneticdevice 308 are both electrically coupled to the battery module 800. Byway of example, power generated by the first electromagnetic device 306and/or the second electromagnetic device 308 may be stored within thebattery module 800, or power stored within the battery module 800 orgenerated elsewhere on the concrete mixer truck 10 may be utilized bythe first electromagnetic device 306 and/or the second electromagneticdevice 308 (e.g., to provide an output torque as a motor, etc.).

According to the exemplary embodiment shown in FIG. 21, the controlsystem 900 includes a user interface 102 that is coupled to thecontroller 910. In one embodiment, the user interface 102 includes adisplay and an operator input. The display may be configured to displaya graphical user interface, an image, an icon, or still otherinformation. In one embodiment, the display includes a graphical userinterface configured to provide general information about the vehicle(e.g., vehicle speed, fuel level, warning lights, etc.). The graphicaluser interface may also be configured to display a current mode ofoperation, various potential modes of operation, or still otherinformation relating to transmission 304, the accessory module 600, orthe drive system 300. By way of example, the graphical user interfacemay be configured to provide specific information regarding theoperation of drive system 400 (e.g., whether the power split coupledclutch 430, the PTO clutch 440, the output coupled clutch 450, and theoutput brake 470 are engaged or disengaged, a fault condition where atleast one of the power split coupled clutch 430, the PTO clutch 440, theoutput coupled clutch 450, and the output brake 470 fail to engage ordisengage in response to a command signal, etc.). By way of anotherexample, the graphical user interface may be configured to providespecific information regarding the accessory module 600 (e.g., whetheran accessory is connected, what type of accessory is connected, statusinformation for the accessory, etc.).

The operator input may be used by an operator to provide commands to atleast one of the transmission 304, the first electromagnetic device 306,the second electromagnetic device 308, the accessory module 600, thedrive system 300, the drum driver 214, the hopper actuator 260, thechute height actuator 280, the chute rotation actuator 282, the chutefolding actuators 284, the airbags 530, the brakes 532, or still anothercomponent of the concrete mixer truck 10. The operator input may includeone or more buttons, knobs, touchscreens, switches, levers, joysticks,or handles. In one embodiment, an operator may press a button to changethe mode of operation for at least one of the transmission 304, thedrive system 300, the drum assembly 200, and the concrete mixer truck10. The operator may be able to manually control some or all aspects ofthe operation of transmission 304 using the display and the operatorinput. The operator input may also control operation of the accessorymodule 600, the mixing drum 202, the hopper 220, the chute 222, theairbags 530, and the brakes 532 (e.g., by controlling one or morevalves, by selectively supplying electrical energy to one or morecomponents, by engaging or disengaging one or more clutches, etc.). Inshould be understood that any type of display or input controls may beimplemented with the systems and methods described herein.

As shown in FIGS. 12 and 21, the control system 900 further includes arotational speed sensor, shown as speed sensor 912, coupled to theoutput shaft 332 within the transmission 304. The speed sensor 912 maybe an optical encoder, a Hall Effect gear tooth sensor, or any othertype of sensor capable of detecting a rotational speed. The speed sensor912 is configured to provide the rotational speed of the output shaft332 to the controller 910. As the output shaft 332 drives the front axleassembly 500 and/or the rear axle assemblies 502, the controller 910 maybe configured to use the rotational speed of the output shaft 332 todetermine a speed of the concrete mixer truck 10 (e.g., a speed oftravel of the concrete mixer truck 10).

The controller 910 may be implemented as a general-purpose processor, anapplication specific integrated circuit (ASIC), one or more fieldprogrammable gate arrays (FPGAs), a digital-signal-processor (DSP),circuits containing one or more processing components, circuitry forsupporting a microprocessor, a group of processing components, or othersuitable electronic processing components. According to the exemplaryembodiment shown in FIG. 21, the controller 910 includes a processingcircuit 914 and a memory 916. The processing circuit 914 may include anASIC, one or more FPGAs, a DSP, circuits containing one or moreprocessing components, circuitry for supporting a microprocessor, agroup of processing components, or other suitable electronic processingcomponents. In some embodiments, the processing circuit 914 isconfigured to execute computer code stored in the memory 916 tofacilitate the activities described herein. The memory 916 may be anyvolatile or non-volatile computer-readable storage medium capable ofstoring data or computer code relating to the activities describedherein. According to an exemplary embodiment, the memory 916 includescomputer code modules (e.g., executable code, object code, source code,script code, machine code, etc.) configured for execution by theprocessing circuit 914. The memory 916 includes various actuationprofiles corresponding to modes of operation (e.g., for the transmission304, for the drive system 300, for the drum assembly 200, etc.),according to an exemplary embodiment. In some embodiments, thecontroller 910 may represent a collection of processing devices (e.g.,servers, data centers, etc.). In such cases, the processing circuit 914represents the collective processors of the devices, and the memory 916represents the collective storage devices of the devices.

Operating Modes of the Power Plant Module

Referring next to the exemplary embodiments shown in FIGS. 22-28, thetransmission 304 is configured to operate according to a plurality ofmodes of operation. Various modes of operation for the transmission 304are identified below in Table 1. In other embodiments, the concretemixer truck 10 having the transmission 304 is configured to operateaccording to the various modes of operation shown in FIGS. 13-19 andidentified below in Table 1.

TABLE 1 Mode of Operation Power Split Output Coupled Output PTO CoupledClutch Clutch Brake Clutch 430 450 470 440 Mid Speed Reverse X X LowSpeed Reverse X X Active Neutral X X Low Range X X Mid Range X X Shift XX X High Range X X

As shown in Table 1, an “X” represents a component of the drive system300 (e.g., the output brake 470, the power split coupled clutch 430,etc.) that is engaged or closed during the respective modes ofoperation. In one embodiment, all of the components in Table 1 aredisengaged to selectively reconfigure the transmission 304 in a neutralmode.

As shown in FIG. 22, the transmission 304 is selectively reconfiguredinto an active neutral mode of operation (e.g., a PTO only mode ofoperation, etc.). The controller 910 may selectively configure thetransmission 304 into the active neutral mode of operation from apassive neutral mode of operation (e.g., a mode whereby the power splitcoupled clutch 430, the PTO clutch 440, the output coupled clutch 450,and the output brake 470 are disengaged such that the firstelectromagnetic device 306 and the second electromagnetic device 308 canrotate without rotating the PTO shaft 602 or the output shaft 332,etc.). In one embodiment, the controller 910 first selectivelyconfigures the transmission 304 into the passive neutral mode ofoperation (e.g., by disengaging the power split coupled clutch 430, thePTO clutch 440, the output coupled clutch 450, and the output brake 470)and thereafter selectively configures the transmission 304 into theactive neutral mode of operation in response to a request to use theaccessory module 600. The transmission 304 may be reconfigured into thepassive neutral mode of operation at various times during the operationof the concrete mixer truck 10 (e.g., when entering a park mode ofoperation from a driving mode of operation, in order to tow the concretemixer truck 10, etc.). By way of example, the active neutral mode ofoperation may be used when the concrete mixer truck 10 is mixing and/ordispensing concrete while stationary (e.g., while in position at a jobsite).

In one embodiment, rotation of the first electromagnetic device 306rotates the PTO shaft 602 to power the accessory module 600. By way ofexample, the first electromagnetic device 306 may be configured to usethe electrical energy from the battery module 800 and provide arotational mechanical energy input (e.g., a torque, etc.) to the PTOshaft 602 through the power split planetary 410 and the connecting shaft336. In another embodiment, rotation of the second electromagneticdevice 308 rotates the PTO shaft 602 (e.g., where the PTO clutch 440 isengaged, etc.) to power the accessory module 600. By way of example, thesecond electromagnetic device 308 may be configured to use theelectrical energy from the battery module 800 and provide a rotationalmechanical energy input (e.g., a torque, etc.) to the PTO shaft 602through the engagement of the PTO clutch 440 with the connecting shaft336. In yet another embodiment, simultaneous rotation of both the firstelectromagnetic device 306 and the second electromagnetic device 308rotates the PTO shaft 602 to power the accessory module 600.

As shown in FIG. 22 and Table 1, the PTO clutch 440 and the output brake470 are engaged when the transmission 304 is configured in the activeneutral mode. As shown in FIG. 22, the PTO clutch 440 directly couplesthe second electromagnetic device 308 to the connecting shaft 336 andthe PTO shaft 602. The output brake 470 rotationally fixes the ring gear424. According to the exemplary embodiment shown in FIG. 22, a firstenergy flow path for the active neutral mode includes: the batterymodule 800 providing electrical energy to the first electromagneticdevice 306; the first electromagnetic device 306 using the electricalenergy and providing a rotational mechanical energy input to the sungear 412 that is received by the plurality of the planetary gears 416;the plurality of the planetary gears 416 conveying the rotationalmechanical energy to the ring gear 414; and the ring gear 414transferring the rotational mechanical energy to the connecting shaft336 such that the rotational mechanical energy provided by the firstelectromagnetic device 306 rotates the PTO shaft 602. A second energyflow path for the active neutral mode includes: the battery module 800providing electrical energy to the second electromagnetic device 308;and the second electromagnetic device 308 using the electrical energyand providing a rotational mechanical energy input to the connectingshaft 336 through the PTO clutch 440 such that the rotational mechanicalenergy rotates the PTO shaft 602. The first and second energy flow pathsmay occur independently (e.g., by running only one electromagneticdevice at one time) or simultaneously.

In an alternative to the active neutral mode of operation, only the PTOclutch 440 engaged, coupling the second electromagnetic device 308 tothe PTO shaft 602. This alternative mode of operation would utilize thesecond energy flow path, which includes: the battery module 800providing electrical energy to the second electromagnetic device 308;and the second electromagnetic device 308 using the electrical energyand providing a rotational mechanical energy input to the connectingshaft 336 through the PTO clutch 440 such that the rotational mechanicalenergy rotates the PTO shaft 602.

In some embodiments, these energy flow paths may be followed in areverse sequence to generate electrical energy. By way of example, thesecond electromagnetic device 308 may be used to apply a braking torqueon the PTO shaft 602. In such an example, rotational mechanical energyis transferred from the PTO shaft 602 to the second electromagneticdevice 308 through the connecting shaft 336 and the PTO clutch 440. Thesecond electromagnetic device 308 removes rotational mechanical energyfrom the PTO clutch 440 and generates electrical energy to charge thebattery module 800. By way of another example, the first electromagneticdevice 306 may be used to apply a braking torque on the PTO shaft 602.In such an example, rotational mechanical energy is transferred from thePTO shaft 602 to the first electromagnetic device 306 through theconnecting shaft 336 and the power split planetary 410. The firstelectromagnetic device 306 removes rotational mechanical energy from thesun gear 412 and generates electrical energy to charge the batterymodule 800. By way of example, such a configuration may be used whenslowing or changing the direction of rotation of the mixing drum 202(e.g., to change between mixing material and dispensing material). Therotating mixing drum 202 may contain a large amount of kinetic energy,especially when filled with material. When slowing or changing thedirection of the mixing drum 202, the momentum of the mixing drum 202may back drive the drum drive motor 252 (e.g., operating the drum drivemotor 252 as a hydraulic pump). The drum drive motor 252 provides a flowof pressurized hydraulic fluid to the drum drive pump 620, driving thedrum drive pump 620 to provide rotational mechanical energy (e.g.,operating the drum drive pump 620 as a hydraulic motor). The drum drivepump 620 then provides rotational mechanical energy to the PTO shaft602.

According to the exemplary embodiment shown in FIG. 22, engaging the PTOclutch 440 rotates the second electromagnetic device 308 at therotational speed of the connecting shaft 336. The connecting shaft 336may rotate at the same speed as the PTO shaft 602 such that the PTOshaft 602 and the second electromagnetic device 308 operate at a 1:1speed ratio. According to the exemplary embodiment shown in FIG. 22,engaging the PTO clutch 440 and the output brake 470 rotates the carrier418 (e.g., through the output planetary 420, etc.) while the ring gear414 rotates with the connecting shaft 336. Engaging the PTO clutch 440and the output brake 470 may drive the first electromagnetic device 306at a rotational speed that is related to the rotational speed of thecarrier 418 and the rotational speed of the ring gear 414. In oneembodiment, the active neutral mode locks the first electromagneticdevice 306 and the second electromagnetic device 308 in a fixed speedratio with the PTO shaft 602 (e.g., 1:1 between the secondelectromagnetic device 308 and the PTO shaft 602; 1.06:1 between thefirst electromagnetic device 306 and the PTO shaft 602, etc.).

Referring still to FIG. 22, the transmission 304 isolates the firstelectromagnetic device 306 and the second electromagnetic device 308from the output shaft 332 during the active neutral mode (e.g., thepower split coupled clutch 430 and the output coupled clutch 450 may bedisengaged, etc.). Such isolation may reduce (e.g., substantiallyeliminate, etc.) a forward lurch potential of the concrete mixer truck10 (e.g., the transmission 304 does not provide an output torque to thefront axle assembly 500 and/or the rear axle assemblies 502 when in theactive neutral mode, etc.).

In some embodiments, at least one of the PTO clutch 440 and the outputbrake 470 are disengaged to prepare the transmission 304 to beselectively reconfigured into a drive mode (e.g., low range, mid range,high range, etc.). By way of example, the PTO clutch 440 may bedisengaged in response to a command from a user (e.g., through the userinterface 102) to enter a drive mode. Only the power split coupledclutch 430 may need to be engaged to selectively reconfigure thetransmission 304 into the mid range mode, thereby providing a simple andefficient process by which the concrete mixer truck 10 may be shiftedinto a drive mode and driven. In some embodiments, when preparing toshift modes of operation, the controller 910 controls the firstelectromagnetic device 306 and/or the second electromagnetic device 308in a motoring mode where the first electromagnetic device 306 and/or thesecond electromagnetic device 308 provide an input torque to thetransmission 304 and are commanded to operate at a target speed. Such aspeed may be based on the current speed of the concrete mixer truck 10(e.g., zero if the concrete mixer truck 10 is not moving on flat ground,non-zero if the concrete mixer truck 10 is rolling up or down a slope atstartup, etc.). Commanding the operation of the first electromagneticdevice 306 and/or the second electromagnetic device 308 may prepare thetransmission 304 for a shift from the active neutral mode of operation(i.e., a selective reconfiguration, etc.) to another driving mode ofoperation (e.g., a mid range mode of operation, etc.). Such preparationmay decrease an inertial jerk on the output shaft 332 during the shift.

As shown in FIG. 23, the transmission 304 is selectively reconfiguredinto a low range mode of operation such that the transmission 304 allowsfor a low output speed operation with a high output torque. The lowrange mode increases the gradability of the concrete mixer truck 10(e.g., facilitates the concrete mixer truck 10 maintaining speed on agrade, etc.). In one embodiment, the second electromagnetic device 308uses the electrical energy from the battery module 800 and provides arotational mechanical energy input to the transmission 304 to drive atleast one of the front axle assembly 500 and the rear axle assemblies502. The rotational mechanical energy input from the secondelectromagnetic device 308 may additionally drive the PTO shaft 602. Inanother embodiment, the first electromagnetic device 306 uses theelectrical energy from the battery module 800 and provides a rotationalmechanical energy input to the transmission 304 to drive at least one ofthe front axle assembly 500, the rear axle assemblies 502, and the PTOshaft 602 in the low range mode. In another embodiment, both the firstelectromagnetic device 306 and the second electromagnetic device 308provide a rotational mechanical energy input to the transmission 304 inthe low range mode. In still another alternative embodiment, one or bothof the first electromagnetic device 306 and the second electromagneticdevice 308 operate as a generator in the low range mode.

In some embodiments, while in the low range mode, the firstelectromagnetic device 306 only provides rotational mechanical energywhen it is desired to operate the accessory module 600. Upon receiving arequest to operate the accessory module 600, the first electromagneticdevice 306 provides rotational mechanical energy to drive the PTO shaft602. The first electromagnetic device 306 may begin providing rotationalmechanical energy to the output shaft 332 when the transmission 304 istransitioned into another mode of operation (e.g., the mid range mode,the high range mode, etc.). In other embodiments, when the concretemixer truck 10 is traveling at less than a threshold speed (e.g., asmeasured using the speed sensor 912), the first electromagnetic device306 only provides rotational mechanical energy when it is desired tooperate the accessory module 600. Upon receiving a request to operatethe accessory module 600, the first electromagnetic device 306 providesrotational mechanical energy to drive the PTO shaft 602. The firstelectromagnetic device 306 may begin providing rotational mechanicalenergy to the output shaft 332 when the concrete mixer truck 10 reachesthe threshold speed. In yet other embodiments, the first electromagneticdevice 306 provides rotational mechanical energy to drive the outputshaft 332 and/or the accessory module 600 when the first electromagneticdevice 306 is in the low range mode and/or regardless of the speed ofthe concrete mixer truck 10.

As shown in FIG. 23 and Table 1, the power split coupled clutch 430 andthe output coupled clutch 450 are engaged when the transmission 304 isconfigured in the low range mode. As shown in FIG. 23, the power splitcoupled clutch 430 and the output coupled clutch 450 couple the gear set480 and the gear set 490 to the output shaft 332, respectively.Accordingly, when the first electromagnetic device 306 and/or the secondelectromagnetic device 308 provide a rotational mechanical energy inputto the transmission 304, both the power split planetary 410 and theoutput planetary 420 drive the output shaft 332 through the gear set 480and the gear set 490, respectively. According to the exemplaryembodiment shown in FIG. 23, an exemplary energy flow path for the lowrange includes: the second electromagnetic device 308 receivingelectrical energy from the battery module 800; the secondelectromagnetic device 308 operating as a motor, providing a rotationalmechanical energy input to the sun gear 422; the sun gear 422 causingthe plurality of planetary gears 426 to rotate about central axesthereof, as well as about the sun gear 422 such that both the carrier428 and the ring gear 424 rotate; the rotation of the ring gear 424driving the gear set 490. The rotation of the carrier 428 drives boththe carrier 418 and the gear set 480. According to the exemplaryembodiment shown in FIG. 23, the gear set 480 and the gear set 490transfer a torque to and from the output shaft 332 with the power splitcoupled clutch 430 and the output coupled clutch 450 engaged. As such,the second electromagnetic device 308 moves the concrete mixer truck 10at a low speed with a high output torque. This energy flow path mayadditionally include: the carrier 418 causing the plurality of theplanetary gears 416 to rotate about central axes thereof, as well asabout the sun gear 412 such that the ring gear 414 rotates; the ringgear 414 providing a rotational mechanical energy input to theconnecting shaft 336; and the connecting shaft 336 conveying therotational mechanical energy to the PTO shaft 602 to drive the accessorymodule 600

According to the exemplary embodiment shown in FIG. 23, a secondexemplary energy flow path for the low range includes: the firstelectromagnetic device 306 receiving electrical energy from the batterymodule 800; the first electromagnetic device 306 operating as a motor,providing a rotational mechanical energy input to the sun gear 412; thesun gear 412 causing the plurality of the planetary gears 416 to rotateabout central axes thereof, such that the ring gear 414 rotates; thering gear 414 providing a rotational mechanical energy input to theconnecting shaft 336; and the connecting shaft 336 conveying therotational mechanical energy to the PTO shaft 602 to drive the accessorymodule 600. This energy flow path may additionally or alternativelyinclude the plurality of the planetary gears 416 rotating about the sungear 412 such that the carrier 418 and the gear set 480 rotate.According to the exemplary embodiment shown in FIG. 23, the gear set 480transfers a torque to and from the output shaft 332 with the power splitcoupled clutch 430 and the output coupled clutch 450 engaged. As such,the first electromagnetic device 306 moves the concrete mixer truck 10at a low speed with a high output torque.

In some embodiments, the second electromagnetic device 308 is coupled tothe output shaft 332 at a fixed ratio through the output planetary 420,the gear set 490, and the output coupled clutch 450 during the low rangemode. Accordingly, the rotational speed of the output shaft 332 isentirely dependent on the rotational speed of the second electromagneticdevice 308. The speed of the PTO shaft 602 is dependent on the relativerotational speed between the first electromagnetic device 306 and thesecond electromagnetic device 308. In the low range mode, the firstelectromagnetic device 306 controls the speed of the sun gear 412, andthe second electromagnetic device 308 controls the speed of the carrier418. Depending on the relative rotational speeds and directions of thesun gear 412 and the carrier 418, the plurality of the planetary gears416 cause the ring gear 414, and thus the PTO shaft 602, to rotate atdifferent speeds and in different directions. Accordingly, the relativerotational speed and direction of the first electromagnetic device 306and the second electromagnetic device 308 may be varied to cause thefirst electromagnetic device 306 to drive the PTO shaft 602, the outputshaft 332, or both, and the second electromagnetic device 308 to drivethe output shaft 332 or both the output shaft 332 and the PTO shaft 602.

In some embodiments, these energy flow paths may be followed in areverse sequence to generate electrical energy. By way of example, thesecond electromagnetic device 308 may be used to apply a braking torqueon the output shaft 332. In such an example, rotational mechanicalenergy is transferred from the output shaft 332 to the secondelectromagnetic device 308 through the output coupled clutch 450, thegear set 490, and the output planetary 420. The second electromagneticdevice 308 removes rotational mechanical energy from the sun gear 422and generates electrical energy to charge the battery module 800 orpower the first electromagnetic device 306. By way of another example,the first electromagnetic device 306 may be used to apply a brakingtorque on the PTO shaft 602. In such an example, rotational mechanicalenergy is transferred from the PTO shaft 602 to the firstelectromagnetic device 306 through the connecting shaft 336 and thepower split planetary 410. The first electromagnetic device 306 removesrotational mechanical energy from the sun gear 412 and generateselectrical energy to charge the battery module 800 or power the secondelectromagnetic device 308.

As shown in FIG. 24, the transmission 304 is selectively reconfiguredinto a mid range mode of operation such that the transmission 304 allowsfor a mid range output speed operation. The mid range mode may improvelow output speed torque and high output speed power. In one embodiment,the second electromagnetic device 308 uses the electrical energy fromthe battery module 800 and provides a rotational mechanical energy inputto the transmission 304 to drive at least one of the front axle assembly500 and the rear axle assemblies 502. The rotational mechanical energyinput from the second electromagnetic device 308 may additionally drivethe PTO shaft 602. In another embodiment, the first electromagneticdevice 306 uses the electrical energy from the battery module 800 andprovides a rotational mechanical energy input to the transmission 304 todrive at least one of the front axle assembly 500, the rear axleassemblies 502, and the PTO shaft 602 in the mid range mode. In anotherembodiment, both the first electromagnetic device 306 and the secondelectromagnetic device 308 provide a rotational mechanical energy inputto the transmission 304 in the mid range mode. In still anotheralternative embodiment, one or both of the first electromagnetic device306 and the second electromagnetic device 308 operate as a generator inthe mid range mode.

As shown in FIG. 24 and Table 1, the power split coupled clutch 430 andthe output brake 470 are engaged when the transmission 304 is configuredin the mid range mode. As shown in FIG. 24, the output brake 470inhibits the rotation of the gear set 490 (e.g., the gear 492, the gear494, the gear 496, etc.) and rotationally fixes the ring gear 424. Inone embodiment, engaging the output brake 470 substantially eliminates apower dip between output and input modes of the transmission 304.According to the exemplary embodiment shown in FIG. 24, an energy flowpath for the mid range mode includes: the second electromagnetic device308 receiving electrical energy from the battery module 800; the secondelectromagnetic device 308 operating as a motor, providing a rotationalmechanical energy input to the sun gear 422; the sun gear 422 causingthe plurality of planetary gears 426 to rotate about central axesthereof, as well as about the sun gear 422 such that the carrier 428rotates; and the rotation of the carrier 428 driving both the carrier418 and the gear set 480. As shown in FIG. 24, the power split coupledclutch 430 couples the gear set 480 to the output shaft 332 such thatthe rotational mechanical energy of the gear set 480, received from thesecond electromagnetic device 308, drives the output shaft 332 at a midrange output speed and may thereby drive the concrete mixer truck 10 ata mid range output speed. The energy flow path may additionally include:the carrier 418 causing the plurality of the planetary gears 416 torotate about central axes thereof, as well as about the sun gear 412such that the ring gear 414 rotates; the ring gear 414 providing arotational mechanical energy input to the connecting shaft 336; and theconnecting shaft 336 conveying the rotational mechanical energy to thePTO shaft 602 to drive the accessory module 600.

According to the exemplary embodiment shown in FIG. 24, a secondexemplary energy flow path for the mid range includes: the firstelectromagnetic device 306 receiving electrical energy from the batterymodule 800; the first electromagnetic device 306 operating as a motor,providing a rotational mechanical energy input to the sun gear 412; thesun gear 412 causing the plurality of the planetary gears 416 to rotateabout central axes thereof, such that the ring gear 414 rotates; thering gear 414 providing a rotational mechanical energy input to theconnecting shaft 336; and the connecting shaft 336 conveying therotational mechanical energy the PTO shaft 602 to drive the accessorymodule 600. This energy flow path may additionally or alternativelyinclude the plurality of the planetary gears 416 rotating about the sungear 412 such that the carrier 418 and the gear set 480 rotate. As shownin FIG. 24, the power split coupled clutch 430 couples the gear set 480to the output shaft 332 such that the rotational mechanical energy ofthe gear set 480, received from the first electromagnetic device 306,drives the output shaft 332 at a mid range output speed and may therebydrive the concrete mixer truck 10 at a mid range output speed.

In some embodiments, the second electromagnetic device 308 is coupled tothe output shaft 332 at a fixed ratio through the output planetary 420,the power split planetary 410, the gear set 480, and the power splitcoupled clutch 430 during the mid range mode. Accordingly, therotational speed of the output shaft 332 is entirely dependent on therotational speed of the second electromagnetic device 308. The speed ofthe PTO shaft 602 is dependent on the relative rotational speed betweenthe first electromagnetic device 306 and the second electromagneticdevice 308. In the mid range mode, the first electromagnetic device 306controls the speed of the sun gear 412, and the second electromagneticdevice 308 controls the speed of the carrier 418. Depending on therelative rotational speeds and directions of the sun gear 412 and thecarrier 418, the plurality of the planetary gears 416 cause the ringgear 414, and thus the PTO shaft 602, to rotate at different speeds andin different directions. Accordingly, the relative rotational speed anddirection of the first electromagnetic device 306 and the secondelectromagnetic device 308 may be varied to cause the firstelectromagnetic device 306 to drive the PTO shaft 602, the output shaft332, or both, and the second electromagnetic device 308 to drive theoutput shaft 332 or both the output shaft 332 and the PTO shaft 602.

In some embodiments, these energy flow paths may be followed in reverseto generate electrical energy. By way of example, the secondelectromagnetic device 308 may be used to apply a braking torque on theoutput shaft 332. In such an example, rotational mechanical energy istransferred from the output shaft 332 to the second electromagneticdevice 308 through the power split coupled clutch 430, the gear set 480,the power split planetary 410, and the output planetary 420. The secondelectromagnetic device 308 removes rotational mechanical energy from thesun gear 422 and generates electrical energy to charge the batterymodule 800 or power the first electromagnetic device 306. By way ofanother example, the first electromagnetic device 306 may be used toapply a braking torque on the PTO shaft 602. In such an example,rotational mechanical energy is transferred from the PTO shaft 602 tothe first electromagnetic device 306 through the connecting shaft 336and the power split planetary 410. The first electromagnetic device 306removes rotational mechanical energy from the sun gear 412 and generateselectrical energy to charge the battery module 800 or power the secondelectromagnetic device 308.

As shown in FIG. 25, the transmission 304 is selectively reconfiguredinto a high range mode of operation such that the transmission 304allows for a high output speed operation. In one embodiment, the secondelectromagnetic device 308 uses the electrical energy from the batterymodule 800 and provides a rotational mechanical energy input to thetransmission 304 to drive the PTO shaft 602 and at least one of thefront axle assembly 500 and the rear axle assemblies 502. In anotherembodiment, the first electromagnetic device 306 uses the electricalenergy from the battery module 800 and provides a rotational mechanicalenergy input to the transmission 304 to drive at least one of the frontaxle assembly 500, the rear axle assemblies 502, and the PTO shaft 602in the high range mode. In another embodiment, both the firstelectromagnetic device 306 and the second electromagnetic device 308provide a rotational mechanical energy input to the transmission 304 inthe high range mode. In still another alternative embodiment, one orboth of the first electromagnetic device 306 and the secondelectromagnetic device 308 operate as a generator in the high rangemode.

As shown in FIG. 25 and Table 1, the power split coupled clutch 430 andthe PTO clutch 440 are engaged when the transmission 304 is configuredin the high range mode. As shown in FIG. 25, the engagement of the PTOclutch 440 with the connecting shaft 336 rotationally couples the secondelectromagnetic device 308 and the PTO shaft 602. By way of example, thesecond electromagnetic device 308 may use electrical energy from thebattery module 800 and provide a rotational mechanical energy input tothe connecting shaft 336 to drive the PTO shaft 602. The PTO shaft 602may also be driven by the first electromagnetic device 306 in the highrange mode. By way of example, the first electromagnetic device 306 mayuse electrical energy from the battery module 800 and provide arotational mechanical energy input to the sun gear 412 that drives thering gear 414 through the planetary gears 416. The ring gear 414transfers rotational mechanical energy to the connecting shaft 336,which drives the PTO shaft 602.

Referring to FIG. 25, in one embodiment, both the first electromagneticdevice 306 and the second electromagnetic device 308 receive electricalenergy from the battery module 800 and provide rotational mechanicalenergy to the transmission 304 to drive the output shaft 332. The firstelectromagnetic device 306 operates as a motor, providing a rotationalmechanical energy input to the sun gear 412 that drives the plurality ofthe planetary gears 416 and the carrier 418. The second electromagneticdevice 308 also acts as a motor. Rotational mechanical energy from thesecond electromagnetic device 308 is transferred to the plurality of theplanetary gears 416 through the connecting shaft 336 and the ring gear414. The plurality of the planetary gears 416 are driven by both thesecond electromagnetic device 308 (e.g., through the ring gear 414,etc.) and the first electromagnetic device 306 (e.g., through the sungear 412, etc.). The carrier 418 rotates, which drives the gear set 480.As shown in FIG. 25, the power split coupled clutch 430 couples the gearset 480 to the output shaft 332 such that the rotational mechanicalenergy provided by the first electromagnetic device 306 and secondelectromagnetic device 308 drives the concrete mixer truck 10 at a highrange speed.

In some embodiments, the second electromagnetic device 308 is coupled tothe PTO shaft 602 at a fixed ratio (e.g., 1:1) through the PTO clutch440 and the connecting shaft 336 during the high range mode.Accordingly, the rotational speed and direction of the PTO shaft 602 isentirely dependent on the rotational speed of the second electromagneticdevice 308. The speed of the output shaft 332 is dependent on therelative rotational speed between the first electromagnetic device 306and the second electromagnetic device 308. In the high range mode, thefirst electromagnetic device 306 controls the speed of the sun gear 412,and the second electromagnetic device 308 controls the speed of the ringgear 414. Depending on the relative rotational speeds and directions ofthe sun gear 412 and the ring gear 414, the plurality of the planetarygears 416 cause the carrier 418, and thus the output shaft 332, torotate at different speeds and in different directions.

In some embodiments, these energy flow paths may be followed in reverseto generate electrical energy. By way of example, the firstelectromagnetic device 306 and the second electromagnetic device 308 maybe used to apply a braking torque on the output shaft 332. In such anexample, rotational mechanical energy is transferred from the outputshaft 332 to the second electromagnetic device 308 through the powersplit coupled clutch 430, the gear set 480, the power split planetary410, the connecting shaft 336, and the PTO clutch 440. Rotationalmechanical energy is transferred from the output shaft 332 to the firstelectromagnetic device 306 through the power split coupled clutch 430,the gear set 480, and the power split planetary 410. The firstelectromagnetic device 306 and the second electromagnetic device 308remove rotational mechanical energy from the sun gear 412 and theconnecting shaft 336, respectively, and generate electrical energy tocharge the battery module 800. By way of another example, the secondelectromagnetic device 308 may be used to apply a braking torque on thePTO shaft 602. In such an example, rotational mechanical energy istransferred from the PTO shaft 602 to the second electromagnetic device308 through the connecting shaft 336 and the PTO clutch 440. The firstelectromagnetic device 306 removes rotational mechanical energy from thesun gear 412 and generates electrical energy to charge the batterymodule 800 or power the second electromagnetic device 308.

As shown in FIG. 26, the transmission 304 is selectively reconfiguredinto an intermediate shift mode of operation that facilitatestransitioning the transmission 304 (i.e., shifting, changing modes,etc.) between the mid range mode of operation and the high range mode ofoperation. According to the embodiment shown in FIG. 26, the PTO clutch440, the power split coupled clutch 430, and the output brake 470 areengaged when the transmission 304 is selectively reconfigured into theintermediate shift mode of operation. According to an exemplaryembodiment, the intermediate shift mode provides a smooth and robustshifting strategy that functions reliably even in a wide variety ofoperating conditions, when using various types of oil for the componentsof the transmission 304, and when experiencing valve nonlinearities thatmay be present in one or more valves of the transmission 304. Theintermediate shift mode may provide a zero inertia shift through andacross two or more overlapping ranges (e.g., the mid range and the highrange, etc.). According to the exemplary embodiment shown in FIGS.15-17, the intermediate shift mode eliminates the need to simultaneouslydisengage the output brake 470 and engage the PTO clutch 440 to shiftfrom the mid range mode to the high range mode, or vice versa. Theintermediate shift mode reduces jerking sensations associated withsimultaneously disengaging the output brake 470 and engaging the PTOclutch 440 to shift from the mid range to high range, providing asmoother ride.

During operation, the intermediate shift mode may be used to shift fromthe mid range mode to the high range mode or from the high range mode tothe mid range mode. In one embodiment, the transmission 304 isconfigured in the mid range mode of operation with the power splitcoupled clutch 430 and the output brake 470 engaged and configured inthe high range mode of operation with the power split coupled clutch 430and the PTO clutch 440 engaged. The transmission 304 may be selectivelyreconfigured into the intermediate shift mode in response to thedifference between a rotational speed of the second electromagneticdevice 308 and a rotational speed of the connecting shaft 336 fallingbelow or equaling a threshold level (e.g., approximately zero, fiverevolutions per minute, fifty revolutions per minute, etc.). Thetransmission 304 may enter the intermediate shift mode when therotational speed of the second electromagnetic device 308 substantiallycorresponds with (e.g., matches, is substantially equal to, etc.) therotational speed of the connecting shaft 336. In one embodiment, thetransmission 304 enters the intermediate shift mode when the rotationalspeeds of the second electromagnetic device 308 and the connecting shaft336 are between 1,600 and 1,800 revolutions per minute (RPM). By way ofexample, the transmission 304 may enter the intermediate shift mode whenthe rotational speeds of the second electromagnetic device 308 and theconnecting shaft 336 are about 1,600 RPM. One or more sensors may bepositioned to monitor the rotational speed of at least one of theconnecting shaft 336, a portion of the second electromagnetic device308, or still another component. A controller (e.g., the controller 910,etc.) may reconfigure the transmission 304 into the intermediate shiftmode in response to sensing signals provided by the one or more sensors.

Shifting into the intermediate shift mode occurs when there is limited(if any) relative movement between clutch disks of the PTO clutch 440.The transmission 304 may be reconfigured into the intermediate shiftmode without compromising performance of the concrete mixer truck 10(e.g., since torque is not removed from the output shaft 332, etc.). Theintermediate shift mode reduces (e.g., minimizes, etc.) heat generationand clutch wear during shifts by limiting the relative movement betweenclutch disks of the PTO clutch 440 upon engagement. The intermediateshift mode may thereby increase clutch life.

In operation, the concrete mixer truck 10 may be accelerating in the midrange mode. In one embodiment, the second electromagnetic device 308provides an output torque in the mid range mode of operation and itsspeed thereby increases with the speed of the concrete mixer truck 10.As the speed of the second electromagnetic device 308 continues toincrease with the speed of the concrete mixer truck 10, the secondelectromagnetic device 308 may begin to operate at a rotational speedsimilar to that of the connecting shaft 336. The controller 910 mayengage the PTO clutch 440 to selectively reconfigure the transmission304 into the intermediate shift mode from the mid range mode. Theconcrete mixer truck 10 may alternatively be decelerating in the highrange mode. In one embodiment, the first electromagnetic device 306operates as a motor in the high range mode of operation with its speedrelated to that of the connecting shaft 336 and/or the speed of theconcrete mixer truck 10. The speed of the concrete mixer truck 10 and/orthe speed of the first electromagnetic device 306 may decrease to aspeed designated for the mid range mode. The controller 910 may beconfigured to utilize the speed of the output shaft 332 provided by thespeed sensor 912 to determine the speed of the concrete mixer truck 10.The controller 910 may engage the output brake 470 to selectivelyreconfigure the transmission 304 into the intermediate shift mode fromthe high range mode.

As shown in FIGS. 15-17, the power split coupled clutch 430 is engaged(i.e., is not disengaged, is not open, transfers torque, etc.) in eachof the mid range mode, the intermediate shift mode, and the high rangemode. The transmission 304 having the power split coupled clutch 430engaged in each of these modes facilitates the continuous transfer ofpower from the first electromagnetic device 306 and the secondelectromagnetic device 308 to the output shaft 332 during the shift fromthe mid range mode to the high range mode. According to an exemplaryembodiment, the first electromagnetic device 306 and the secondelectromagnetic device 308 are also coupled to the output shaft 332through the power split coupled clutch 430 at a fixed ratio during theintermediate shift mode. Maintaining a power path to the output shaft332 during the shift reduces (e.g., eliminates, etc.) jerking associatedwith shifting traditional transmission systems. In the intermediateshift mode, an acceleration of the first electromagnetic device 306 andthe second electromagnetic device 308 causes an acceleration of theconcrete mixer truck 10, and a deceleration of the first electromagneticdevice 306 and the second electromagnetic device 308 causes adeceleration of the concrete mixer truck 10.

The transmission 304 may be configured in the intermediate shift modefor an extended period of time and/or while the while the concrete mixertruck 10 traverses an extended distance. The controller 910 mayselectively reconfigure the transmission 304 out of the intermediateshift mode (e.g., into the mid range mode of operation, into the highrange mode of operation, etc.) automatically in response to at least oneof an elapsed shift time (e.g., a time that has elapsed while in theintermediate shift mode, etc.), a traveled shift distance (e.g., adistance the concrete mixer truck 10 has traveled while in theintermediate shift mode as determined using the speed sensor 912, etc.),a change in speed of the connecting shaft 336, the speed of the concretemixer truck 10 (e.g., as determined using the speed sensor 912, etc.)exceeding or falling below a threshold speed of the concrete mixer truck10, and a request, among other conditions.

In one embodiment, the controller 910 transitions the transmission 304out of the intermediate shift mode in response to an indication that theshift has satisfied at least one of a time-based and a distance-basedcondition. By way of one example, the controller 910 may transition thetransmission 304 out of the intermediate shift mode in response to anindication that the transmission 304 has been in the intermediate shiftmode for longer than a predetermined period of time. By way of anotherexample, the controller 910 may transition the transmission 304 out ofthe intermediate shift mode in response to an indication that theconcrete mixer truck 10 has traversed more than a threshold distance(e.g., as determined using the speed sensor 912).

In another embodiment, the controller 910 transitions the transmission304 out of the intermediate shift mode in response to a change in speedof the connecting shaft 336. The controller 910 may selectivelyreconfigure the transmission 304 into the high range mode from theintermediate shift mode (e.g., by disengaging the output brake 470,etc.) in response to an increase in speed of the connecting shaft 336(e.g., in response to the speed of the connecting shaft 336 exceeding athreshold speed, etc.). By way of example, the speed of the connectingshaft 336 may increase based on a command (e.g., provided by an operatorusing an accelerator pedal or another input device, provided by acontroller as part of an autonomous operation of the concrete mixertruck 10, etc.) that prompts the speed of the connecting shaft 336 toincrease. The controller 910 may selectively reconfigure thetransmission 304 into the mid range mode from the intermediate shiftmode (e.g., by disengaging the PTO clutch 440, etc.) in response to adecrease in speed of the connecting shaft 336 (e.g., in response to thespeed of the connecting shaft 336 falling below a threshold speed,etc.). By way of example, the speed of the connecting shaft 336 maydecrease based on a command (e.g., provided by an operator using a brakepedal or another input device, provided by an operator releasing anaccelerator pedal or another input device, provided by a controller aspart of an autonomous operation of the concrete mixer truck 10, etc.)that prompts the speed of the connecting shaft 336 to decrease.

In still another embodiment, the controller 910 transitions thetransmission 304 out of the intermediate shift mode in response to arequest. By way of example, the request may come from an operator (e.g.,provided by way of a user interface, etc.) and indicate the operator'scommand to enter either the mid range mode of operation or the highrange mode of operation. The request may also be provided by acontroller as part of an autonomous operation of the concrete mixertruck 10. Such requests may be provided in order to reenter a mode ofoperation whereby the concrete mixer truck 10 operates more efficiently.Such requests may prompt the transmission 304 to complete the shift fromthe mid range mode of operation to the high range mode of operation,complete the shift from the high range mode of operation to the midrange mode of operation, toggle back into the mid range mode ofoperation from the intermediate shift mode, and/or toggle back into thehigh range mode of operation from the intermediate shift mode.

In some embodiments, the transmission 304 is selectively reconfiguredinto the intermediate shift mode from one of the mid range mode and thehigh range mode, and then is selectively reconfigured back into theprevious mode (e.g., mid range mode to intermediate shift mode to midrange mode, etc.). By way of example, the transmission 304 may bereconfigured into the intermediate shift mode from the mid range mode inresponse to the second electromagnetic device 308 and the connectingshaft 336 having a speed differential below a threshold level. Anoperator may keep the connecting shaft 336 operating at substantiallythe same speed for a period of time, driving the output shaft 332 withthe first electromagnetic device 306 and/or the second electromagneticdevice 308, and then release the accelerator pedal whereby thetransmission 304 may be returned to the mid range mode.

As shown in FIG. 27, the transmission 304 is selectively reconfiguredinto a low speed reverse mode of operation. In one embodiment, thesecond electromagnetic device 308 uses the electrical energy from thebattery module 800 and provides a rotational mechanical energy input tothe transmission 304 to drive at least one of the front axle assembly500 and the rear axle assemblies 502 in a reverse direction (e.g.,backwards, etc.) in the low speed reverse mode. The rotationalmechanical energy input from the second electromagnetic device 308 mayadditionally drive the PTO shaft 602. In another embodiment, the firstelectromagnetic device 306 uses the electrical energy from the batterymodule 800 and provides a rotational mechanical energy input to thetransmission 304 to drive at least one of the wheel and tire assemblies508 and the wheel and tire assemblies 508 in a reverse direction and/orto drive the PTO shaft 602 in the low speed reverse mode. In anotherembodiment, both the first electromagnetic device 306 and the secondelectromagnetic device 308 provide a rotational mechanical energy inputto the transmission 304 in the low speed reverse mode. In still anotheralternative embodiment, one or both of the first electromagnetic device306 and the second electromagnetic device 308 operate as a generator inthe low speed reverse mode.

As shown in FIG. 27 and Table 1, the power split coupled clutch 430 andthe output coupled clutch 450 are engaged when the transmission 304 isconfigured in the low speed reverse mode. As shown in FIG. 27, the lowspeed reverse mode is substantially similar to the low range mode ofFIG. 23 in that the power split coupled clutch 430 and the outputcoupled clutch 450 couple both the gear set 480 and the gear set 490 tothe output shaft 332. In the low speed reverse mode, the firstelectromagnetic device 306 and/or the second electromagnetic device 308may provide a rotational mechanical energy input to the transmission 304in an opposite direction as compared to the low range mode of FIG. 23.

As shown in FIG. 28, the transmission 304 is selectively reconfiguredinto a mid speed reverse mode of operation such that the transmission304 allows for a moderate reverse output speed operation. In oneembodiment, the second electromagnetic device 308 uses the electricalenergy from the battery module 800 and provides a rotational mechanicalenergy input to the transmission 304 to drive at least one of the frontaxle assembly 500 and the rear axle assemblies 502 in a reversedirection in the mid speed reverse mode. The rotational mechanicalenergy input from the second electromagnetic device 308 may additionallydrive the PTO shaft 602. In another embodiment, the firstelectromagnetic device 306 uses the electrical energy from the batterymodule 800 and provides a rotational mechanical energy input to thetransmission 304 to drive at least one of the wheel and tire assemblies508 and the wheel and tire assemblies 508 in a reverse direction and/orto drive the PTO shaft 602 in the mid speed reverse mode. In anotherembodiment, both the first electromagnetic device 306 and the secondelectromagnetic device 308 provide a rotational mechanical energy inputto the transmission 304 in the mid speed reverse mode. In still anotheralternative embodiment, one or both of the first electromagnetic device306 and the second electromagnetic device 308 operate as a generator inthe mid speed reverse mode.

As shown in FIG. 28 and Table 1, the power split coupled clutch 430 andthe output brake 470 are engaged when the transmission 304 is configuredin the mid speed reverse mode. As shown in FIG. 28, the mid speedreverse mode is substantially similar to the mid range mode of FIG. 24in that the output brake 470 inhibits the rotation of the gear set 490(e.g., the gear 492, the gear 494, the gear 496, etc.) and rotationallyfixes the ring gear 424. In the mid speed reverse mode, the firstelectromagnetic device 306 and/or the second electromagnetic device 308may provide a rotational mechanical energy input to the transmission 304in an opposite direction as compared to the mid range mode of FIG. 24.

Battery Module

In some embodiments, the battery module 800 provides all of the energyused to power the concrete mixer truck 10 in at least one mode ofoperation. In some such embodiments, the battery module 800 provides allof the energy used to power the concrete mixer truck 10 in all modes ofoperation, except when the battery module 800 is being charged by anoutside power source (e.g., mains power from the power grid, etc.). Asdescribed above, such a concrete mixer truck 10 may be a pure electricvehicle. In other such embodiments, an onboard engine (e.g., an internalcombustion engine) provides some or all of the energy used to power theconcrete mixer truck 10 in some modes of operation. Such a concretemixer truck 10 may be a hybrid vehicle.

In modes of operation where the battery module 800 provides all of theenergy used to power the concrete mixer truck 10, the battery module 800provides electrical energy to drive the first electromagnetic device 306and/or the second electromagnetic device 308. As described in detailabove, the first electromagnetic device 306 and/or the secondelectromagnetic device 308 may use the electrical energy to providerotational mechanical energy to the transmission 304. The transmission304, the front drive shaft 510, the rear drive shaft 520, and the reardrive shaft 524 transfer a first portion of the rotational mechanicalenergy to the front axle assembly 500 and the rear axle assemblies 502,which propel the concrete mixer truck 10. The transmission 304 and thePTO shaft 602 transfer a second portion of the rotational mechanicalenergy to the accessory module 600. The accessory module 600 consumesthe second portion of the rotational mechanical energy and providesflows of pressurized working fluid (e.g., pressurized hydraulic fluidand compressed gas) and/or electrical energy. The flows of pressurizedhydraulic fluid drive the drum drive motor 252, the hopper actuator 260,the chute height actuator 280, the chute rotation actuator 282, and thechute folding actuators 284. Flows of compressed air drive the airbags530 and the brakes 532. A flow of compressed refrigerant drives aclimate control system. The electrical energy from the accessory module600 charges the battery 642 and powers various systems of the concretemixer truck 10.

In some embodiments, one or more of the drum drive motor 252, the hopperactuator 260, the chute height actuator 280, the chute rotation actuator282, and the chute folding actuators 284 are electrically driven (i.e.,powered using electrical energy) rather than hydraulically driven (i.e.,powered using pressurized hydraulic fluid). By way of example, one ofthe actuators may be replaced with an electric motor or an electricmotor coupled to a device that converts rotational movement into linearmovement, such as a lead screw. Such electrically driven actuators maybe powered using electrical energy from the battery module 800 orelectrical energy from the alternator 640 and/or battery 642. In someembodiments, the drum drive pump 620 and/or the accessory pump 622 maybe omitted. In one embodiment, the drum drive motor 252, the hopperactuator 260, the chute height actuator 280, the chute rotation actuator282, and the chute folding actuators 284 are all electrically driven. Insuch an embodiment, both the drum drive pump 620 and the accessory pump622 may be omitted.

In some embodiments, one or more of the airbags 530 and the brakes 532are electrically driven (i.e., powered using electrical energy) ratherthan pneumatically driven (i.e., powered using compressed gas). By wayof example, the airbags 530 may be replaced with an electric motor or anelectric motor coupled to a device that converts rotational movementinto linear movement, such as a lead screw. Such electrically drivenactuators may be powered using electrical energy from the battery module800 or electrical energy from the alternator 640 and/or battery 642. Insome embodiments, the drivetrain compressor 630 may be omitted.

In other embodiments, one or more components of the accessory module 600(e.g., the drum drive pump 620, the accessory pump 622, the drivetraincompressor 630, the air conditioning compressor 632, the alternator 640)are decoupled from the PTO shaft 602 and driven by an electric motor.Such an electric motor may be driven by electrical energy from thebattery module 800 or by electrical energy from the alternator 640.

Frame

Referring to FIGS. 29, 30A, and 30B, the battery module 800 includes aframe, shown as battery module frame 810. The battery module frame 810is coupled to the chassis 20 near the rear end 24. The battery moduleframe 810 is configured to releasably support any number of differenttypes of primary power sources. The battery module frame 810 includesthree panels or platforms, shown as base portions 812. The base portions812 are each vertically offset from one another to provide spaces toplace components. The base portions 812 are each coupled to a series ofstructural members or supports, shown as vertical supports 814. Thevertical supports 814 are positioned at the corners of the base portions812 and couple the base portions 812 to one another. As shown in FIG. 1,the battery module frame 810 is covered by a shroud or housing, shown asbattery module cover 816. In some embodiments, battery module cover 816may be removable.

As noted above, the battery module frame 810 is positioned rearwardrelative to the rear axle assembly 502, such that the weight of thebattery module frame 810 and battery module 800 supported thereonoffsets the weights of the cab 100, the drive system 300 (described inmore detail above), and the mixing drum 202 which are each positionedforward of the rear axle assembly 502. Specifically, as illustrated inFIG. 1, in some embodiments, the center of gravity of the cab 100(offset a distance D₃ rearward from a center of the front axle assembly500), the drive system 300 (offset a distance D₅ rearward from a centerof the front axle assembly 500), and the mixing drum 202 (offset adistance D₆ rearward from a center of the front axle assembly 500) areeach positioned forward of a point P_(RT) centered between the rear axleassembly 502, and the center of gravity of the battery module frame 810and attached battery module 800 (offset a distance D₁₂ rearward from acenter of the front axle assembly 500) is positioned rearward of thepoint P_(RT). Accordingly, the moments of the weights of the cab 100,the drive system 300, and the mixing drum 202 about the point P_(RT)oppose the moments of the weight of the battery module frame 810 andattached battery module 800 about the point P_(RT). This ensures thatthe weight of the concrete mixer truck 10 and its payload issubstantially evenly distributed between the front axle assembly 500 andrear axle assembly 502. This also ensures that the front axle assembly500 is not lifted away from the ground due to the moment effect of theweight of the battery module frame 810 and attached battery module 800about the point P_(RT), which may otherwise make the concrete mixertruck 10 more difficult to steer.

Mounting Structure

Illustrated in FIGS. 30A and 30B is one exemplary embodiment of abattery module frame 810 that may be used to support one or more batteryassemblies 820 of the battery module 800. As shown in FIG. 30A, in someembodiments the battery module frame 810 includes support members 811 towhich the base portion 812 is releasably secured, as briefly describedabove. In this manner, battery module frame 810 may be releasablysecured to the chassis 20 via the support members 811. The supportmembers 811 may be attached permanently (e.g. via welding) ornon-permanently (via any number of known attachment arrangements) to thechassis 20. Provided along the base portion 812 and support members 811are any number of, and combination of, various engagement structures 813that are configured to releasably secure the base portion 812 and thesupport members 811 to one another.

In embodiments in which a first battery module 800 or other primarypower source (e.g., an internal combustion engine) is to be replacedwith a second, different type of primary power source or battery module800, the support members 811 may be modified to conform to the shape andstructure of the battery module 800 or primary power source to ensure asecure connection of the second battery module 800 to the concrete mixertruck 10. Alternatively, in some embodiments, the support members 811may be entirely replaced with second, new support members 811,configured to securely support the second battery module 800 or theprimary power source may instead be provided with the battery module 800or primary power source. In some such embodiments, the second, newsupport members 811 may include the same type, spacing and configuration(and optionally the same number) of engagement structures 813 as wereprovided on the first support members 811, such that the new supportmembers 811 and base portion 812 may be securely connected to oneanother using substantially the same engagement structures 813.

In other embodiments, the battery module frame 810 may be defined by anynumber of other, different arrangements that are configured toreleasably secure the battery module 800 to the chassis 20 and whichallow for easy and quick removal of the battery module 800 from theconcrete mixer truck 10. For example, according to some embodiments, thebattery module frame 810 may comprise only the base portion 812 securelyattached to the chassis 20, with the battery module 800 being configuredto be directly and releasably be coupled to the base portion 812 of thebattery module frame 810. In yet other embodiments, the battery moduleframe 810 may be configured to be releasably secured directly to thechassis 20 of the concrete mixer truck 10 via engagement structures 813.

Referring now to FIG. 31A, an alternate embodiment is shown, in whichthe battery module 800 is supported by a mounting plate 1102 rather thanby support members 811. In some embodiments, another type of primarypower source, such as an internal combustion engine, may be supported bythe mounting plate 1102. Alternatively, as illustrated in FIG. 31B,according to other embodiments, the battery module frame 810 mayadditionally include a second support plate 1104 releasably attached tothe mounting plate 1102 or the support members 811, with the batterymodule 800 being releasably, or alternatively irremovably, attached tothe support plate 1104 or the support members 811. Similar, in someembodiments, another type of primary power source, such as an internalcombustion engine, may be releasably, or alternatively irremovably,attached to the support plate 1104 or the support members 811.

In some embodiments, one or more attachment structures 1120 areconfigured to securely, but releasably engage the battery module 800and/or one or more of the mounting elements defining the battery moduleframe 810 relative to the concrete mixer truck 10. In some suchembodiments, the attachment structures 1120 may be functionally similarto or the same as engagement structure 813. As will be understood, anynumber of, or combination of attachment structures 1120 may be used tosecure the battery module 800 relative to the concrete mixer truck 10until it is desired to remove the battery module 800 from the concretemixer truck 10. For example, as shown in FIG. 31A, in some embodiments,the attachment structure may include one or more fastening assemblies.In such embodiments, the fastening assemblies may comprise any numberof, or combination of, fastening elements formed along or defined by afirst mounting element defining the battery module frame 810 (e.g. alongthe mounting structure) that are configured to engage with correspondingfastening structures that are provided as discrete elements (e.g. bolts,etc.) and/or are formed along or defined by another element of themounting assembly (e.g. the support plate 1104).

Referring to FIG. 31B, according to other embodiments, the batterymodule frame 810 may be defined by a post, door, or other retainingstructure that is configured to act as barrier that blocks movement ofthe battery module 800. In such embodiments, the battery module frame810 is configured to be detached, slid, pivoted, or otherwise movedrelative to at least one mounting element defining the battery moduleframe 810, to allow the battery module 800 to be removed from theconcrete mixer truck 10. For example, as shown in FIG. 1, in some suchembodiments, the attachment structure may include an optionally providedbattery module cover 816 configured to secure the battery module 800 tothe concrete mixer truck 10 when the cover is attached to the chassis(or other portion of the concrete mixer truck 10), with the removal ofthe battery module cover 816 being configured to allow the batterymodule 800 to be removed from the concrete mixer truck 10.

In some embodiments, the attachment structures 1120 are only intendedand configured to releasably secure the battery module 800 to theconcrete mixer truck 10. However, as will be described in more detailbelow, according to other embodiments, in addition to securing thebattery module 800 to the concrete mixer truck 10 during use of theconcrete mixer truck 10, the attachment structures 1120 may additionallybe configured to define a component of, or otherwise be useable with,the removal assembly 1200 to remove the battery module 800 from theconcrete mixer truck 10.

Removal Assembly

Although the various embodiments of removal assemblies 1200 describedherein may refer to a particular mounting assembly arrangement via whichthe battery module 800 is attached to the concrete mixer truck (e.g. viaa support plate 1104 releasably attached to a battery module frame 810;via a direct and releasable attachment to the battery module frame 810;etc.), it is to be understood that in other embodiments, any of theremoval assemblies 1200 described herein may be modified so as to removea battery module 800 secured to the concrete mixer truck 10 via anyother battery module frame 810 arrangement. Additionally, although thevarious embodiments of removal assemblies 1200 described herein mayrefer to the removal assembly 1200 being configured to engage one ormore specific mounting elements (e.g. the support plate 1104, thebattery module frame 810, etc.) and/or the battery module 800 duringremoval, it is to be understood that in other embodiments (such as,e.g., when a different battery module frame 810 arrangement is used tosecure the battery module 800 to the concrete mixer truck 10), any ofthe removal assemblies 1200 described herein may be modified such thatthe removal assembly 1200 engages any other combination of one or moremounting elements and/or the battery module 800 during the removal ofthe battery module 800 form the concrete mixer truck 10.

The removal assembly 1200 is configured to facilitate removal of thebattery module 800 from the concrete mixer truck 10. As will bedescribed in more detail below, the removal assembly 1200 may be definedby a variety of removal elements configured to interact with one anotherto remove the battery module 800 from the concrete mixer truck 10, and,in some embodiments, to transfer the battery module 800 to a charginglocation. According to various embodiments, the removal assembly 1200may additionally be configured to attach the battery module 800 to theconcrete mixer truck 10. It will be appreciated that, while the removalassembly 1200 is described herein for removing or attaching the batterymodule 800 to the concrete mixer truck 10, the removal assembly 1200 mayalso be configured to remove and/or attach a different primary powersource (e.g., an internal combustion engine) from the concrete mixertruck 10. In this manner, the removal assembly 1200 may facility theretrofitting of the battery module 800 to the concrete mixer truck 10.

In some embodiments, the removal assembly 1200 may be entirely definedby removal elements supported by the concrete mixer truck 10. In otherembodiments, the removal assembly 1200 may additionally include one ormore externally provided removal elements. In some such embodiments, theexternally provided removal elements may be defined by existing devicesand/or structures that are incorporated into, or utilized with, theremoval assembly 1200. In other embodiments, the externally providedremoval elements may be defined by devices and/or structures that havebeen specifically made or adapted to be used in the removal assembly1200.

According to various embodiments, the removal assembly 1200 may beconfigured to remove the battery module from the concrete mixer truck ata location that generally corresponds to the charging location. In somesuch embodiments, once the removal assembly 1200 has removed the batterymodule 800 from the concrete mixer truck 10, the battery module 800 mayremain attached to or otherwise supported by a portion of the removalassembly 1200, such that the removal assembly 1200 also defines acharging station. For example, according to some embodiments, theremoval assembly 1200 may include a support structure having a supportsurface that is configured to engage the removed battery module 800. Inother embodiments, once the battery module 800 has been removed, theremoval assembly 1200 may be configured to set the battery module 800onto any number of existing, non-specific support surfaces (e.g., afloor surrounding the removal assembly 1200, a loading dock surface,etc.) that extend adjacent the location of the removal assembly 1200.

Referring to FIGS. 32A-32C, exemplary embodiments of removal assembly1200 comprising one or more externally provided removal elements areillustrated. As shown in FIGS. 32A-32C, according to some suchembodiments, the externally provided removal elements may be defined byany number of various external lift devices 1202, such as, e.g., a fork,hoist, crane, jack, boom, etc. In such embodiments, these lift devices1202 are configured to engage one or more engagement elements 1210provided along the battery module 800 to lift the battery module 800 offof the concrete mixer truck 10. The engagement elements 1210 may bedefined by any number of, and combination of, different configurations.Non-limiting examples of such engagement element 1210 configurations arerepresentatively illustrated in FIGS. 32A-32C, and may include, e.g.,handles (such as, e.g., shown in FIG. 32A); recesses (such as, e.g.shown in FIG. 32B); channels (such as, e.g., shown in FIG. 32C), etc.Upon removal of the battery module 800 from the concrete mixer truck 10,the externally provided lift device 1202 may additionally be configuredto transfer the battery module 800 to a charging location, eitherdirectly by the lift device 1202 itself, or via one or more transportdevices to which the battery module 800 is transferred by the liftdevice 1202.

According to other embodiments, instead of relying on the availabilityand/or accessibility of an externally provided lift device 1202, theremoval assembly 1200 may instead include one or more lift devices 1202provided as a part of the concrete mixer truck 10. The lift device 1202may be defined by any number of powered and/or manually operateddevices, such as, e.g. a jack lift, a lift cylinder, etc. In someembodiments, the lift device 1202 may be releasably attached to thebattery module 800, with the lift device 1202 being disengaged from thebattery module 800 prior to the concrete mixer truck 10 being drivenaway from the removed battery module 800. In other embodiments, the liftdevice 1202 may instead be fixedly attached to the battery module 800and releasably attached to the concrete mixer truck 10, with the liftdevice 1202 remaining with the removed battery module 800 after theconcrete mixer truck 10 is driven away.

In embodiments in which the removal assembly 1200 includes a lift device1202 provided by the concrete mixer truck 10, the removal assembly 1200may additionally include one or more support structures 1220 configuredto support the battery module 800 such that the concrete mixer may bedriven away once the battery module 800 has been sufficiently raised bythe lift device 1202. Referring to FIGS. 33A and 33B, in someembodiments, the support structure 1220 may be externally provided. Insuch embodiments, any number of different types of, or configurationsof, engagement elements 1210 may be used to attach the battery module800 to the externally provided support structure 1220. For example, asshown in FIG. 33A, in some embodiments, hook or handle shaped engagementelements 1210 formed on one of the battery module 800 and the externalsupport structure 1220 may be configured to engage a correspondingretention elements 1215 formed on the other of the external supportstructure 1220 and battery module 800.

Turning to FIG. 33A-33B, in other embodiments in which the removalassembly 1200 includes a lift device 1202 supported by the concretemixer truck 10, support of the battery module 800 in the elevatedposition relative to the concrete mixer truck 10 may alternatively, oradditionally, be accomplished by placing the battery module 800 atop anexternally provided support structure 1220. As illustrated in FIG. 33B,according to some embodiments, once the battery module 800 has beenelevated by the lift device 1202, a movable support structure 1220defining a support surface 1225 may be positioned underneath theelevated battery module 800 so as to allow the battery module 800 to besupported thereon. In some embodiments, the movable support structure1220 may be entirely mobile, allowing the battery module 800 to beremoved from the concrete mixer truck 10 at any location at which themobile support structure 1220 may be used. In other embodiments thesupport structure 1220 may be partially mobile, with support surface1225 of the support structure 1220 being movable relative to astationary portion of the support structure 1220. In such embodiments,once the concrete mixer truck 10 has been positioned near supportstructure 1220, the support surface 1225 may be moved as necessary intoalignment with the battery module 800. As illustrated in FIG. 33B, inyet other embodiments, the support structure 1220 may be entirelystationary, with the concrete mixer truck 10 being brought intoproximity with the support structure 1220 and aligned with the supportsurface 1225 of the support structure 1220 to remove the battery module800.

Referring to FIGS. 34A and 34B, according to some embodiments, inaddition to the lift device 1202 being supported by the concrete mixertruck 10, the support structures 1220 of the removal assembly 1200 mayadditionally also be supported by the concrete mixer truck 10 so as todefine a removal assembly 1200 entirely supported by the concrete mixertruck 10. As will be understood, removal assembly 1200 embodiments suchas those illustrated in FIGS. 34A and 34B, which do not rely on anyexternal removal elements to remove the battery module 800,advantageously free the battery module 800 to be removed from theconcrete mixer truck 10 at substantially any location and in anysituation.

As shown in FIG. 34A, according to one embodiment of a self-supportedremoval assembly 1200, the lift device 1202 is initially operated toraise the battery module 800 to an elevated position, following which apair of fixed or adjustable length leg elements 1230 may be attached,pivoted downward, or otherwise engaged to the battery module 800 and soas to bring the lower surfaces of the leg elements 1230 into contactwith the ground on either side of the concrete mixer truck 10. Once theleg elements 1230 have been engaged with the ground, the concrete mixertruck 10 may be driven away, leaving the battery module 800 supported bythe leg elements 1230.

Turning to FIG. 34B, in some self-supported removal assembly 1200embodiments, instead of the lift device 1202 and the leg elements 1230being discrete removal elements, the lift device 1202 and one or more ofthe leg elements 1230 of the removal assembly 1200 may instead (oradditionally) be integrated into a single structure. As illustrated inFIG. 34B, the integrated leg/lift elements 1235 may be defined by atelescoping, articulating, or otherwise expandable structure. When it isdesired to remove the battery module 800, the expandable leg/liftelements 1235 are actuated, thereby initiating an extension of theleg/lift elements 1235. The leg/lift elements 1235 continue to extend ina generally downwards direction until the leg/lift elements 1235 comeinto contact with the ground, at which point continued extension of theleg/lift elements 1235 causes the battery module 800 to be liftedupwards relative to the concrete mixer truck 10. Once the battery module800 has been raised to provide sufficient clearance relative to theconcrete mixer truck 10, the concrete mixer truck 10 may be driven away,leaving the battery module 800 supported by the integrated leg/liftelements 1235.

As also shown in FIG. 34B, in concrete mixer truck 10 embodiments inwhich a width of the rear portion of the concrete mixer truck 10 isgreater than the width of the battery module 800, fixed length ortelescoping horizontal extension elements 1233 may be attached on eitherside of the battery module 800 to extend the width of the battery module800 such that the leg elements 1230 engaged to the battery module 800may clear the sides of the concrete mixer truck 10 and be brought intocontact with the ground.

As shown in FIGS. 33A and 35A, according to some embodiments in whichthe removal assembly 1200 includes a concrete mixer truck 10 supportedlift device 1202 that remains attached to the battery module 800 uponremoval of the battery module 800 from the concrete mixer truck 10, oncethe battery module 800 has been engaged by the support structure 1220 tosupport the battery module 800 so as to allow the concrete mixer truck10 to drive away, the lift device 1202 may optionally be configured tobe further extended until the lift device 1202 is brought into contactwith the ground, thus providing additional support for the weight of theremoved battery module 800 in addition to that provided by theexternally provided support structure 1220 and/or the support structure1220 provided as part of the concrete mixer truck 10 (e.g. leg elements1230 and/or leg/lift elements 1235).

As will be understood, in embodiments in which the configuration of therear end of the concrete mixer truck 10 is such that the battery module800 does not need to be elevated relative to the concrete mixer truck 10to permit the concrete mixer truck 10 to be driven away, the lift device1202 may optionally be omitted from the removal assembly 1200. Forexample, in some such embodiments, the removal assembly 1200 may insteadrely solely on the battery module 800 being supported via the engagementbetween the engagement elements 1210 provided along one of the batterymodule 800 and external support structure 1220 and the retentionelements 1215 provided along the other of the battery module 800 andexternal support structure 1220.

In other embodiments, instead of entirely omitting a lift device 1202from the removal assembly 1200, the lift device 1202 may instead bereplaced by an elevated structure 1204, with the battery module 800being supported atop the elevated structure 1204 such that a lowersurface of the battery module 800 is positioned vertically above anystructures of the concrete mixer truck 10 rear portion, thereby allowingthe concrete mixer truck 10 to be driven away once that battery module800 has been engaged to an appropriate support structure 1220. As willbe understood, in some such embodiments, the elevated structure 1204 ofthe removal assembly 1200 may be defined as a structure that is distinctand discrete from any of the mounting elements defining the batterymodule frame 810. In other embodiments, the elevated structure 1204 mayinstead be defined by one or more of the mounting elements of thebattery module frame 810. For example, as illustrated in FIG. 35, insome embodiments, a mobile support structure 1220 including a supportsurface 1225 may be positioned into a gap 1206 defined by a U-shapedelevated structure 1204 that is also defines the support plate 1104 ofthe battery module frame 810 atop which the battery module 800 issupported.

According to yet other embodiments, the removal assembly 1200 may bedefined by any number of other configurations and structures configuredto move the battery module 800 along any one of, or any combination of,a lateral axis, a longitudinal axis, and/or a vertical axis relative tothe battery module frame 810 and concrete mixer truck 10 to remove thebattery module 800 from the concrete mixer truck 10.

For example, as illustrated in FIG. 36, in some embodiments, the removalassembly 1200 may include a telescoping, articulating, or otherwiseexpandable structure 1240 to which the battery module 800 is attached,and via which the battery module 800 may be removed from the concretemixer truck 10. When it is desired to remove the battery module 800,attachment structures 1120 of the battery module frame 810 areunsecured, and the expandable structure 1240 is extended from itsconstrained, transport configuration into an extended removalconfiguration. As the expandable structure 1240 is extended, theattached battery module 800 is moved outwards relative to the rearand/or a left of right side of the concrete mixer truck 10, from wherethe battery module 800 may be transferred to a support surface 1225 of asupport structure 1220 located adjacent a rear and/or side of theconcrete mixer truck 10.

Once the battery module 800 has been transferred to the support surface1225, the battery module 800 may be disengaged from the expandablestructure 1240 and/or the expandable structure 1240 may be disengagedfrom the battery module frame 810 (or other portion of the concretemixer truck 10 to which the expandable structure 1240 is attached),thereby removing the battery module 800 from the concrete mixer truck 10and allowing the concrete mixer truck 10 to drive off. The supportsurface 1225 onto which the battery module 800 is transferred may insome embodiments define the charging location of the battery module 800,or may be a temporary location from which the battery module 800 issubsequently transferred (using any number of or combination of devices)to the charging location.

Referring to FIGS. 37A-37C, in other embodiments, the removal assembly1200 may be configured to pivot the battery module 800 about thehorizontal axis or the vertical axis to transfer the battery module 800onto a support surface 1225 of a support structure 1220 extending alonga rear and/or side of the concrete mixer truck 10. As illustrated inFIG. 37A, according to some embodiments, the removal assembly 1200 mayinclude a hinged connector 1258 along which the battery module 800 isattached to a side or a rear edge of the battery module frame 810. Whenit is desired to remove the battery module 800, an edge of the batterymodule 800 located opposite the battery module 800 edge attached to thehinged connector 1258 may be raised, causing the battery module 800 tobe pivoted about the hinged connector and onto a support surface 1225provided alongside the concrete mixer truck 10. Once the battery module800 has been transferred to the support surface 1225, battery module maybe disengaged from the hinged connector 1258 and/or the hinged connector1258 is disengaged from the battery module frame 810.

As shown in FIG. 37B, according to yet other embodiments, the pivotingof the battery module 800 off of the concrete mixer truck 10 and onto asupport structure 1220 may be accomplished via a lift plate 1260attached hingedly to the battery module frame 810 at a first end andattached to the battery module frame 810 via an extendable leg 1262 at asecond end. The battery module 800 is supported on the lift plate 1260such that upon actuation of the lift plate 1260 to extend the extendableleg, the lift plate 1260 (with attached battery module 800) is pivotedrelative to the concrete mixer truck 10.

As shown yet other embodiments (not shown), the removal assembly 1200may include a pin provided on one or both of a left side and a rightside and/or on one or both of a front surface and rear surface of thebattery module 800. The pin is configured to travel along an arcuategroove defined by a side wall structure, thereby facilitating thepivoting transfer of the battery module onto a support surface 1225provided alongside the concrete mixer truck 10. Once the battery module800 has been transferred to the support surface 1225, the pin may bedisengaged from the side wall structure 1256 and/or the battery module800 may be disengaged from the pin.

In other embodiments, instead of pivoting the battery module 800 about ahorizontal axis to remove the battery module 800 from the concrete mixertruck 10, the battery module 800 may instead be removed from theconcrete mixer truck 10 by pivoting the battery module 800 relative tothe vertical axis. As shown in FIG. 37C, according to one suchembodiment, the battery module 800 may be attached to the concrete mixertruck 10 via a pivoting plate 1265. In some embodiments, the pivotingplate 1265 may be a structure discrete from and independent of thebattery module frame 810. In other embodiments, the pivoting plate 1265may define an additional mounting element of the battery module frame810. The pivoting plate 1265 may be pivotally attached to the concretemixer truck at one or more locations about the perimeter of the pivotingplate 1265 to allow the pivoting plate 1265 and attached battery moduleto be moved outwards relative to a side and/or rear of the concretemixer truck 10. As will be understood, in embodiments in which thepivoting plate 1265 is pivotally attached to the concrete mixer truck 10at one or more locations, a user may selectively disengage all but asingle pivotable connection depending on the location of the supportsurface 1225 relative to the concrete mixer truck 10, thus allowing thepivoting plate 1265 to be used to remove the battery module 800irrespective of the positioning the concrete mixer truck 10 relative tothe support structure 1220.

According to some embodiments, the battery module 800 is configured tobe removed from the battery module frame 810 by sliding, pushing,rolling or otherwise moving the battery module 800 laterally off of thebattery module frame 810 and onto a support surface 1225 of a supportstructure 1220 of the removal assembly 1200. More specifically, in suchembodiments, when it is desired to remove the battery module 800 fromthe concrete mixer truck 10, the rear of the concrete mixer truck 10 isbrought into proximity to the support structure 1220 (e.g., by backingthe concrete mixer truck 10 up towards the support structure 1220 and/orby bringing a mobile support structure 1220 towards the rear of theconcrete mixer truck 10). Once the rear of the concrete mixer truck 10and the support structure 1220 have been so aligned and the batterymodule frame 810 unsecured, the battery module 800 is moved off of thebattery module frame 810 of the concrete mixer truck 10 and onto thesupport structure.

Referring to FIGS. 38A-38D, according to some embodiments, the batterymodule 800 may be secured to the concrete mixer truck 10 by a loadhandling system (LHS). In some embodiments, the LHS is a hydraulic orelectric hooklift system for hooking, lifting, and/or hoisting thebattery module 800 onto the rear end 24 of the concrete mixer truck 10.The LHS may include at least a controller 1282 and an arm 1280. The LHSmay also include a series of hydraulic actuators configured to actuatethe arm 1280 (not shown).

The arm 1280 may be configured to actuate to engage the battery module800, as shown in FIG. 38B. For example, the arm 1280 may pivot at one ormore joints and/or about one or more horizontal or vertical axes toengage the battery module 800. In such embodiments, a hook or othersuitable member at a distal end of the arm 1280 may engage acorresponding ring, hook, etc. on the battery module 800. The arm 1280may then actuate to move the battery module 800 onto the concrete mixertruck 10.

As shown in FIGS. 38C-38D, in some embodiments, the battery module 800may be located behind the cab 100 of the concrete mixer truck 10 ratherthan at a rear end of the concrete mixer truck 10. The battery module800 may be behind the cab 100 for rear discharge concrete mixer trucks,for example. In such embodiments, the LHS may be configured to engagethe battery module 800 from a left or right side of the vehicle. Forexample, as shown in FIG. 38D, the battery module may be loaded and/orunloaded from the concrete mixer truck 10 from a left (i.e., driver'sside) of the concrete mixer truck 10.

According to various such embodiments, one or more transfer elements1270 configured to facilitate the lateral movement of the battery module800 off of the concrete mixer truck 10 may be provide along one or bothof the battery module 800 and the battery module frame 810. For example,as shown in FIGS. 39A and 39B, according to various embodiments, thetransfer elements 1270 may be defined by structures such as wheels,linear bearings, rollers, or any other number of rolling structuresconfigured to allow the battery module 800 to be rolled across asurface. In other embodiments, the transfer elements 1270 mayadditionally, or alternatively, be defined by a continuous track or beltassembly.

As shown in FIG. 39A, according to some embodiments, the transferelements 1270 may be configured to allow the battery module 800 to bemoved in an unrestricted, or substantially unconstrained manner relativeto the concrete mixer truck 10. In other embodiments, such as, e.g.illustrated in FIG. 39B, transfer elements 1270 provided on one of thebattery module 800 and the battery module frame 810 may alternatively beconfigured to travel along a track 1273 or other structure formed on theother of the battery module frame 810 and battery module 800, and whichis configured to guide the movement of the transfer elements 1270 alonga predetermined path. As also shown in FIG. 39B, according to some suchembodiments, a support structure 1220 of a removal assembly 1200 mayadditionally include transfer element 1270 or a track 1273 formed aboutthe support surface 1225, so as to further facilitate removal of thebattery module 800.

In some situations, it may not be possible to bring the concrete mixertruck 10 and the support structure 1220 close enough to one another soas to define a substantially uninterrupted surface extending between theupper surface of the battery module frame 810 and the support surface.For example, the lower surface of the battery module 800 may extend at adifferent height than the support surface 1225; the configuration of thesupport structure 1220 and/or the rear of the concrete mixer truck 10may prevent the rear of the concrete mixer truck 10 and the supportstructure 1220 from being brought into close proximity with one another;etc. Accordingly, in some embodiments, an optional extension surface1280 may be provided to bridge any gap between the support surface 1225and the battery module 800, thus providing a substantially continuoussurface along which the battery module 800 may be moved. According tosome embodiments, the extension surface 1280 may optionally include oneor more of the same transfer elements 1270 as those provided along thebattery module and/or battery module frame 810.

In some embodiments, the extension surface 1280 may be provided as anunattached, free structure. In other embodiments, the extension surface1280 may be attached along at least a first end to a structure of theconcrete mixer truck 10. For example, as illustrated in FIG. 39A, insome embodiments, the extension surface 1280 may be attached to aportion of the battery module frame 810, and in some embodiments, mayadditionally define the battery module frame 810 of the battery moduleframe 810. During use of the concrete mixer truck 10, the extensionsurface 1280 may be arranged to extend relative to the battery module800 in such an arrangement as to prevent movement of the battery module800 relative to the battery module frame 810. When it is desired toremove the battery module, the extension surface 1280 may be unsecured,resulting in both the battery module 800 being freed to be removed fromthe concrete mixer truck 10 and, if desired, in the extension surface1280 being capable of being used to bridge a gap extending between theconcrete mixer truck 10 and the support structure 1220.

As described herein, according to various removal assembly 1200embodiments, the battery module 800 is configured to be removed from theconcrete mixer truck 10 by moving the battery module 800 in a specificdirection (e.g. rearwards, to a side, etc.) relative to the concretemixer truck 10. As will be understood, in certain situations, it may notbe possible to align the concrete mixer truck 10 relative to the supportstructure 1220 in such a manner as wound be required to remove thebattery module 800 from the concrete mixer truck 10 using the removalassembly 1200. As such, according to various embodiments, the batterymodule frame 810 may be configured to rotatably attached the batterymodule 800 to the concrete mixer truck 10, such that the battery module800 may be rotated as needed to align the one or more removal assembly1200 components to allow the battery module 800 to be removed from theconcrete mixer truck.

In some embodiments, the battery module 800 may be lifted, slid, orotherwise moved on to or off of the concrete mixer truck 10, as shown inFIG. 40. In such embodiments, for example, the concrete mixer truck 10may pull into a designated spot (e.g., a loading bay) within proximityof the support surface 1225 (e.g., a loading dock, a raised platform,etc.). In some embodiments, the battery module 800 may be transferredbetween the concrete mixer truck 10 and the support surface 1225 by thetransfer element 1270 or a track 1273, as described above. In otherembodiments, another mechanism may be used to slide or move the batterymodule 800 between the support surface 1225 and the concrete mixer truck10. For example, any of the methods and systems described herein may beused to transfer the battery module 800 between the support surface 1225and the concrete mixer truck 10, as shown in FIG. 40.

Referring now to FIGS. 41-42B, the battery module 800 may be configuredto be carried (i.e., transported) by a trailer, in some embodiments. Asshown in FIGS. 41-42B, for example, the battery module 800 may befixedly or removably coupled to a battery module trailer 818. In suchembodiments, coupling the battery module 800 to the battery moduletrailer 818 may allow the battery module 800 to be selectively coupledto the concrete mixer truck 10. In this manner, the battery module 800may be decoupled from the concrete mixer truck 10 in order to charge orreplace the battery module 800. Advantageously, the battery moduletrailer 818 may provide a quick and easy method for replacing depletedbattery modules 800. For example, during operations of the concretemixer truck 10, a low or depleted battery module 800 may be replaced bydecoupling a first battery module trailer 818 from the concrete mixertruck 10 and subsequently coupling a second battery module trailer 818to the concrete mixer truck 10.

The battery module trailer 818 includes a chassis 1420 configured tosupport the various components of the battery module 800. The chassis1420 includes a pair of frame rails 1430 coupled with intermediate crossmembers, according to an exemplary embodiment. As shown in FIG. 41, theframe rails 1430 extend in a generally-horizontal and longitudinaldirection (e.g., extend within 10 degrees of perpendicular relative to avertical direction, extend within ten degrees of parallel relative to aground surface when the battery module trailer 818 is positioned on flatground, etc.) between a front end and a rear end of the battery moduletrailer 818. The frame rails 1430 may be elongated “C”-channels ortubular members, according to various exemplary embodiments. In otherembodiments, the frame rails 1430 include another type of structuralelement (e.g., monocoque, a hull, etc.). In still other embodiments, theframe rails 1430 include a combination of elongated C-channels, tubularmembers, a monocoque element, and/or a hull element.

The battery module trailer 818 is shown to include a pair of tractiveassemblies, shown as trailer axle assemblies 1402. The trailer axleassemblies 1402 may be spaced apart so that the battery module trailer818 may be freestanding when decoupled from the concrete mixing truck10. In some embodiments, the trailer axle assemblies are non-driven ornon-powered. In other embodiments, the trailer axle assemblies 1402 maybe driven, such as by the drive system 300 or by a separate motor orprime mover of the battery module trailer 818. For example, in someembodiments, the battery module trailer 818 may include one or moremotors (e.g., electric motors) for driving the trailer axle assemblies1402.

The trailer axle assemblies 1402 may include brakes (e.g., disc brakes,drum brakes, air brakes, etc.), gear reductions, steering components,wheel hubs, wheels, tires, and/or other features. As shown in FIG. 41,for example, the trailer axle assemblies 1402 each include tractiveelements, shown as wheel and tire assemblies 508. In other embodiments,the trailer axle assemblies 1402 include a different type of tractiveelement (e.g., a track, etc.). In some embodiments, the trailer axleassemblies 1402 may be coupled to the frame rails 1430 via a suspensionsystem. In such embodiments, the suspension system may include numerouscomponents including shocks, struts, springs, leaf springs, etc.

As described with respect to FIGS. 30A and 30B, the battery module frame810 may include support members 811 to which the base portion 812 isreleasably secured, as briefly described above. With respect to thebattery module trailer 818 described herein, the support members 811 maybe attached permanently (e.g. via welding) or non-permanently (via anynumber of known attachment arrangements) to the chassis 1420 the batterymodule trailer 818 rather than, or in addition to, the chassis 20 of theconcrete mixer truck 10. In this manner, battery module frame 810 may bereleasably secured to the chassis 1420 via the support members 811.

As shown in FIG. 41, for example, the battery module trailer 818 may beconfigured to be rotatably and removably coupled to the concrete mixertruck 10. In this example, the battery module trailer 818 includes aframe member shown as tongue 1404. In various embodiments, the tongue1290 may be fixed, detachable, or foldable and may be configured in anysuitable style. An end of the tongue 1404 may include a first couplingmember 1292, such as a kingpin, that may selectively engage with asecond coupling member 1294 (e.g., a fifth-wheel coupling) to rotatablycouple the first coupling member 1292 to the second coupling member 1294about a vertical axis. Together, the first coupling member 1292 and thesecond coupling member 1294 form a coupling assembly 1290 that allowsthe battery module trailer 818 to pivot with respect to the concretemixer truck 10. In some embodiments, the coupling assembly 1290 ispowered (e.g., hydraulically, electrically, etc.) to couple the batterymodule trailer 818 to the concrete mixer truck 10. In other embodiments,the coupling assembly 1290 is not powered and may be manuallyengaged/disengaged to couple/decouple the battery module trailer 818 andthe concrete mixer truck 10.

In some embodiments, the battery module trailer 818 may be configured asa non-pivoting trailer, as shown in FIGS. 42A and 42B. In other words,the battery module trailer 818 may be fixedly and removably coupled tothe concrete mixer truck 10 such that the battery module trailer 818 hasa fixed position and orientation relative to the concrete mixer truck10. In some embodiments, the battery module trailer 818 may beconfigured without the tongue 1404. In such embodiments, the frame rails1430 of the battery module trailer 818 may align with the frame rails 30of the concrete mixer truck. The frame rails 1430 may be coupled to theframe rails 30 by any suitable method. For example, the frame rails 1430may be bolted to the frame rails 30 or may be connected by a couplingassembly. In other embodiments, where the battery module trailer 818includes the tongue 1404, the tongue 1404 may include a couplingassembly 1296 that selectively and removably couples the battery moduletrailer 818 to the concrete mixer truck 10.

The coupling assembly 1296 may include any suitable components forremovably coupling the battery module trailer 818 to the concrete mixertruck 10. In one non-limiting example, the coupling assembly 1296 maycouple battery module trailer 818 to the concrete mixer truck 10 in amanner similar to a removable gooseneck trailer. In this example, aportion of the coupling assembly 1296 connected to the rear end 24 ofthe concrete mixer truck 10 may include a hook, latch, or locking tabassembly, while a portion of the coupling assembly 1296 connected to acorresponding end of the frame 1420 of the battery module trailer 818may include a plurality of alignment protrusions. The battery moduletrailer 818 may then be coupled to the concrete mixer truck 10 byaligning the alignment protrusions with corresponding openings in theportion of the coupling assembly 1296 connected to the rear end 24 ofthe concrete mixer truck 10 and engaging the hook, latch, or locking tabassembly (e.g., manually such as by inserting a rod, by engaging anactuator, hydraulically, etc.).

When configured as a non-pivoting trailer, as shown in FIGS. 42A and42B, the battery module trailer 818 may act as a dolly, similar to aload span tag axle. The battery module trailer 818 may act to distributethe weight of the concrete mixer truck 10 and the battery module 800more evenly and/or across additional axles (e.g., trailer axleassemblies 1402). In some embodiments, the weight distribution andadditional axle assemblies associated with the battery module trailer818 may allow for heavier battery modules (e.g., battery module 800)such that the capacity of the battery module 800 may be increased,leading to increased operational capacity (e.g., increased runtime).

Referring now to FIG. 43A-43C, the battery module 800 may be configuredas a frame slide-out, in some embodiments. The battery module 800 may beconfigured as a frame slide-out for rear discharge concrete mixertrucks, for example. As shown, for example, the battery module 800 maybe configured to mount between the frame rails 30 of the concrete mixertruck 10. In some embodiments, the battery module 800 may span thelength of the concrete mixer truck 10, thereby distributing the weightof the battery module 800. In other embodiments, the battery module 800may be located near a center point of the concrete mixer truck 10, ornear the rear end 24 of the concrete mixer truck 10. In someembodiments, the battery module 800 located underneath the concretemixer truck 10 is a primary or a secondary battery module, where asecond battery module (e.g., a second one of the battery module 800) maybe mounted on the concrete mixer truck 10. The second battery module 800may be located behind the cab 100, as shown, for example, or may belocated at the rear end 24 of the concrete mixer truck 10, and may beconfigured as the primary or the secondary battery.

In one example, the battery module 800 located underneath the concretemixer truck 10 (e.g., between frame rails 30) may be a primary battery,configured to provide energy for normal or reduced operations of theconcrete mixer truck 10 (e.g., moving the concrete mixer truck 10 arounda storage yard). In this example, the second battery module 800, shownbehind the cab 100, may be selectively loaded to increase theoperational capacity of the concrete mixer truck. For example, a secondbattery module may be loaded onto the concrete mixer truck 10 in orderto extend the range or the operating time of the concrete mixer truck10.

In some embodiments, the battery module 800 may be removed (e.g., forcharging or replacement) or installed by sliding the battery module 800out of the front end 22 or the rear end 24 of the concrete mixer truck10. As shown in FIG. 43C, for example, the battery module 800 may beremoved by sliding the battery module 800 forward, between the framerails 30, and out the front end 24 of the concrete mixer truck. In somesuch embodiments, removing the battery module 800 may include removing afront cover or a front bumper of the concrete mixer truck. In otherembodiments, the battery module 800 may be mounted below a front bumperor front cover the concrete mixer truck 10 to facilitate battery moduleremoval or replacement.

Secondary Battery System

As noted above, in some situations a user may be provided with two ormore battery modules 800, allowing a depleted battery module 800 to bereplaced with a charged battery module 800 as needed using any of thebattery module 800 removal assemblies 1200 described herein. In suchsituations, the replacement of the depleted battery module 800 with acharged battery module 800 allows the user to continue operating theconcrete mixer truck 10 as desired.

However, a replacement battery module 800 may not always be available toa user. Accordingly, in various embodiments, the concrete mixer truck 10may be provided with one or more features configured to allow for atleast a limited degree of use of the concrete mixer truck 10 while thebattery module 800 is being charged.

According to various embodiments, the concrete mixer truck 10 may beprovided with a secondary battery 1160 configured as backup source ofpower that may be used to power some or all of the components of theconcrete mixer truck 10 when the battery module 800 has been removed forcharging and/or in other situations in which the battery module 800 isnot able to power the concrete mixer truck 10. According to someembodiments, the secondary battery 1160 may be configured to power someor all of the concrete mixer truck 10 components only when the concretemixer truck 10 is not being powered by the battery module 800. In otherembodiments, the secondary battery 1160 may be used to power some or allof the concrete mixer truck 10 components simultaneously with the use ofthe battery module 800 to power the concrete mixer truck 10.

In some embodiments, the secondary battery 1160 may be entirely separateand discrete from the battery module 800. In some such embodiments, thesecondary battery 1160 may additionally be located at an entirelydiscrete location of the concrete mixer truck 10 (not shown). In suchembodiments, the secondary battery 1160 may optionally be integratedinto and substantially irremovable from the concrete mixer truck 10. Inother embodiments, despite being separate and discrete from the batterymodule 800, the secondary battery 1160 may be mounted to the concretemixer truck 10 at a location that is substantially similar to thelocation at which the battery module 800 is mounted. In suchembodiments, the secondary battery 1160 may optionally be configured tobe attached physically and/or operatively to the same power hub (e.g.battery cooling system, power distribution system, etc.) to which thebattery module 800 is attached. As will be understood, according to suchembodiments in which the secondary battery 1160 is entirely separate anddiscrete from the battery module 800, the secondary battery 1160 remainsattached to the concrete mixer over substantially the entire use of theconcrete mixer truck 10.

In some embodiments, the secondary battery 1160 may be defined by aportion of the battery module 800. As shown in FIG. 44 and described indetail with respect to FIGS. 49-53, according to various embodiments,the battery module 800 may be defined by a plurality of interconnected,detachable battery assemblies 820. In some such embodiments, one or moreof the battery assemblies 820 defining the battery module 800 mayselectively define the secondary battery 1160 over the course of use ofthe concrete mixer truck 10. More specifically, according to someembodiments, the removal assembly 1200 may be configured to selectivelyremove only a portion of the battery assemblies 820 defining the batterymodule 800 for charging, while leaving one or more battery assemblies820 attached to the battery module frame 810. In such embodiments, thosebattery assemblies 820 left attached to the battery module frame 810 maydefine the secondary battery 1160 that is configured to continue topower some or all of the operations of the concrete mixer truck 10 asthe remaining battery assemblies 820 are charged. In order to allow forsuch a selective removal of battery assemblies 820 from the concretemixer truck 10, according to various embodiments, the removal assembly1200 may include one or more of the same or different removal elementsconfigured to assist in removing select battery assemblies 820.

For example, as shown in FIG. 45 in some embodiments in which thesecondary battery 1160 is defined by one or more of the batteryassemblies 820 of the battery module 800, the battery module 800 may bedefined by two or more stacked layers of battery assemblies 820, withone or more battery assemblies 820 being supported by support shelves1130 of the battery module frame 810. In some such embodiments, theremoval assembly may include transfer elements 1270 defined by tracksattached to the walls extending between adjacent support shelves 1130.Formed along the sides of the battery assemblies 820 may be transferelements 1270 defined by one or more rollable elements configured toslide along the tracks attached to the walls 1135 of the mountingassembly. When it is desired to charge the battery module 800, one ormore of the battery assemblies 820 may be removed from the batterymodule frame 810 by sliding the battery assemblies 820 outward from thebattery module frame 810 and onto a support surface, while leaving atleast one battery assembly 820 attached to the battery module frame 810to define the secondary battery 1160. In a subsequent charging event,the one or more battery assemblies 820 that defined the secondarybattery 1160 may be removed for charging, while leaving one or more ofthe previously charged battery assemblies 820 to define the secondarybattery 1160.

According to various embodiments, besides providing a removal assembly1200 configured to allow the selective removal of a portion of thebattery assemblies 820 from the concrete mixer truck, the concrete mixertruck 10 may additionally be provided with one or more features toprevent or avoid situations in which the concrete mixer truck 10 is leftwithout sufficient power required for it operation. In some embodiments,the battery module frame 810 and/or removal assembly 1200 may beconfigured to as to prevent, or initially block, a user from removingall of the battery assemblies 820 from the battery module frame 810, soas to avoid an unintentional situation in which the concrete mixer truck10 is left without power. For example, in the embodiment described withreference to FIG. 45, according to some embodiments, the removalassembly 1200 and/or battery module frame 810 may include one or morefeatures that would prevent all of the battery assemblies 820 being slidoutwards from the shelves via the removal assembly 1200 transferelements 1270 simultaneously unless overridden by a user. In such anembodiment, upon removal of the penultimate battery assembly 820 fromits support shelf 1130, a lock prevents movement of the transferelements 1270 of the remaining, unremoved battery assembly 820 may betriggered, thereby preventing the last battery assembly 820 from beingremoved from the concrete mixer truck 10.

According to other embodiments, the concrete mixer truck 10 may beprovided with a power control module via which the user may selectwhether the secondary battery 1160 is to be used simultaneously with orindependent of the use of the battery module 800 and/or via which theuser may be able to select which, if any, of the components of theconcrete mixer truck 10 are to be operated using the secondary battery1160. In yet other embodiments, the concrete mixer truck 10 mayoptionally also, or alternatively, include a low-power mode that isautomatically activated in response to the available power from thebattery module 800 and/or secondary battery 1160 decreasing below apredetermined threshold. For example, in embodiments in which thesecondary battery 1160 is used exclusively or primarily as a backuppower source, upon detection of the battery module 800 being below apredetermined capacity, the secondary battery 1160 may be configured tolimit the supply of power to certain non-critical components of theconcrete mixer truck 10 until the battery module 800 has beenreplaced/recharged and/or the low-power mode has been overridden by auser. In yet other embodiments in which the secondary battery 1160 isused exclusively or primarily as a backup power source, the secondarybattery 1160 may optionally also, or alternatively, be configured toprevent removal of the battery module 800 if the capacity of thesecondary battery 1160 is detected to be below a threshold level (orunless the overridden by a user). In such a manner, situations in whichthe concrete mixer truck 10 is rendered entirely inoperable shortlyand/or immediately after removing the battery module 800 may beprevented or minimized.

Exemplary Method of Replacing the Primary Power Source

As described herein, the concrete mixer truck 10 battery module frame810 and accessory module 600 are each configured to facilitate theability of a user to replace a first primary power source (e.g., aninternal combustion engine, a first battery module) with a second,different type of primary power source (e.g., battery module 800) with aminimal amount of effort, time, and money. In particular, the easilyaccessible arrangement of the primary power source at the rear of theconcrete mixer truck 10 (as opposed to, e.g., conventional concretemixer truck configurations in which the power source is integratedwithin the concrete mixer truck) provides a user to with easy access tothe primary power source without requiring disassembly of the concretemixer truck 10.

The attachment of the battery module 800 to the concrete mixer truck 10using a releasable battery module frame 810 as described above furtherfacilitates the removal of the battery module 800 from the concretemixer truck 10. In addition to allowing the battery module 800 to beeasily detached and removed from the concrete mixer truck 10, theengagement structures 813 allow the user to easily reuse at least aportion of the battery module frame 810 to support a second, differenttype of battery module 800, thus obviating the need to make anystructural modifications to the chassis 20 when it is desired to replacethe primary power source with a new, different type of primary powersource.

Additionally, the centralized, substantially universal arrangement andintegration of drive elements provided by the accessory module 600minimizes, or obviates, the need for a user to disassemble, replace,reconfigure and/or modify the concrete mixer truck 10 to accommodate thevarious drive elements that would otherwise be necessitated by thesubstitution of a first type of primary power source with a second,different type of primary power source.

According to various embodiments, the initial configuration of theconcrete mixer truck 10 may include an accessory module (e.g., theaccessory module 600) that is provided according to varying levels ofcompleteness. For example, in some embodiments, the concrete mixer truck10 may be provided with a fully integrated and assembled accessorymodule 600, in which all of the drive elements of the concrete mixertruck 10 are operably coupled to second end 605 of a PTO shaft 602extending from the transmission 304. In such embodiments, when it isdesired to retrofit the concrete mixer truck 10 with a second, differenttype of primary power source, the conversion of the concrete mixer truck10 may require only that a user remove the primary power source (e.g., afirst battery module 800) from the battery module frame 810, andreattach to the battery module frame 810 the second primary powersource.

According to other embodiments, the accessory module 600 may be providedin a partially arranged configuration in which a portion of the driveelements of the concrete mixer truck 10 are operably attached to thesecond end 605 of the PTO shaft 602 in an initial configuration of theconcrete mixer truck 10. In such embodiments, some or all of theremaining drive elements may be structurally or otherwise operablyattached to the first primary power source, such that the removal of theprimary power source results in the removal of these drive elements fromthe concrete mixer truck 10 as well. Accordingly, in some embodiments,the process of retrofitting the concrete mixer truck 10 to include asecond, different type primary power source may include incorporatingsome or all of the drive elements removed with the primary power sourceinto the accessory module 600. As will be understood, in embodiments inwhich not all of the removed drive elements are incorporated into theaccessory module 600, some or all of these drive elements that are notincorporated into the accessory module 600 may instead be attached to orotherwise operably connected to the new, second primary power source. Aswill be understood, in embodiments in which the second primary powersource of the concrete mixer truck 10 is replaced one or more times, anydrive elements that are removed with the replaced primary power sourcemay similarly either be incorporated into the accessory module 600, ormay be attached to the replacement primary power source.

In yet other embodiments, the concrete mixer truck 10 may initially beprovided without an accessory module 600. In such embodiments, uponreplacement of the first primary power source, the concrete mixer truck10 may be provided with an accessory module 600 by operably attaching afirst end 603 of a PTO shaft 602 to the transmission 304, and attachingsome or all of the drive elements removed with the removal of the firstbattery primary power source to a second end 605 of the PTO shaft 602.The PTO shaft 602 may be provided either as a new, discrete structure,or as a modified existing structure of the concrete mixer truck 10 (e.g.as a shortened a drive shaft that was operably attached to a removedengine-based primary power source). Any remaining drive elements may beattached to the second primary power source. With subsequentreplacements of the primary power source, some or all of the driveelements removed with the removal of the primary power source may beadded to the accessory module or may be reincorporated into the concretemixer truck 10 via an attachment to the replacement primary powersource.

Referring to FIGS. 46A and 46B, a block diagram illustrating a methodaccording to one exemplary embodiment of converting an engine-basedconcrete mixer truck 10 to being powered by a battery module is shown.Referring to FIG. 46A, in an initial, engine-based configuration of theconcrete mixer truck 10, a drive shaft operably connects the engine tothe transmission 304, and optionally to the one or more electromagneticdevices 306, 308. As also shown in FIG. 46A, according to someembodiments of a concrete mixes truck 10 having an initial configurationdefined by an engine-based primary power source, all of the driveelements of the concrete mixer truck may be directly of otherwiseoperably attached to the engine, such that the concrete mixer truck 10does not initially includes an accessory module. As shown in FIG. 46B,upon replacing the engine with a battery module that is operablyattached to the electromagnetic device 306, 308, the drive shaft may beremoved from the concrete mixer truck 10, with a first end 603 of a PTOshaft being reattached to the transmission 304 in place of the driveshaft. Alternatively, in some embodiments, the drive shaft may beshortened (e.g. by cutting, using a telescoping structure, etc.) toconvert the drive shaft into the PTO shaft 602. The drive elementsremoved with the removal of the engine-based primary power source maythen be supported by the frame and operably attached to the second end605 of the PTO shaft 602. In embodiments in which not all of the driveelements are integrated into the accessory module, some or all of theremaining drive elements may be operably attached to the battery-modulebased primary power source.

In some embodiments, it may be anticipated that a concrete mixer truckincluding an initially engine-based primary power source may eventuallybe converted into an exclusively electric powered vehicle having abattery-module based primary power source (e.g., battery module 800).Accordingly, as illustrated in FIGS. 47A and 47B, in some embodiments,the concrete mixer truck 10 may include at least a partially configuredaccessory module 600 provided with the initial engine-based primarypower source. As shown in FIG. 47A, in such embodiments, the PTO shaft602 operably attached to the transmission 304 may be provided inaddition to a drive shaft extending between the transmission 304 and theengine. In some such embodiments, all of the drive elements may beattached to the engine in the original configuration of the concretemixer truck 10, with some or all of the drive elements being integratedinto the accessory module 600 with the conversion of the concrete mixertruck 10 to a battery-module based primary power source, as e.g.illustrated in FIG. 47B. Alternatively, in some embodiments, at leastsome of the drive elements may initially be operably attached to the PTOshaft 602 in the initial engine-based concrete mixer truck 10configuration, with some or all of the remaining drive elements beingintegration into the accessory module 600 with the substitution of theengine with a battery module. In yet other embodiments, all of the driveelements may be operably attached to the PTO shaft 602 in theengine-based concrete mixer truck 10 configuration. As will beunderstood, in such embodiments, once it is desired to convert theconcrete mixer truck 10 to an exclusively electric-powered, batterymodule-based vehicle, it may be sufficient to remove and replace theengine and attached drive shaft with a battery module (e.g., batterymodule 800).

Power Management

Turning to the block diagram of FIG. 48, according to variousembodiments, a power management system 830 is defined by a batterymodule 800, a charging port 802, a traction inverter 842, and a tractionmotor 1304. In various embodiments, the traction motor 1304 may comprisetwo or more electromagnetic devices, such as the first electromagneticdevice 306 and/or the second electromagnetic device 308. For example,the traction motor 1304 may be functionally similar to or the same as atleast a portion of drive systems 300 or 1000. As also shown in FIG. 48,the power management system 830 may optionally also include a drum driveinverter 1306 and the drum drive motor 252 of the concrete mixer truck10. The drum drive inverter 1306, for example, may be included when thedrum driver 214 is electrically powered. As will be described with morereference to FIGS. 57-66 below, according to various embodiments, thepower management system 830 may include any number of, or combination ofadditional components configured to filter or otherwise modify the flowof electricity through the power management system 830.

In addition to the one or more filtering or otherwise charge modifyingelements that may be incorporated into the power management system 830,according to various embodiments, any number of other additional systemsor components may also be incorporated into and/or used with the powermanagement system 830. For example, the power management system 830 mayinclude a junction box that may include couplers, such as, e.g., busbars that electrically couple various components of the power managementsystem 830. The junction box may also include one or more powerdisconnect devices, such as, e.g., breakers, fuses, etc. configured toelectrically decouple components when needed, such as, e.g., when thecurrent flowing therethrough exceeds a threshold level. In variousembodiments, the power management system 830 may also include any numberof different cooling system components and arrangements that areconfigured to remove thermal energy from one or more of the othercomponents of the power management system 830.

The battery module 800, as described herein, may be defined by one ormore individual battery units (e.g., lithium ion batteries, lead acidbatteries, nickel-cadmium batteries, etc.) that store energy chemically.Alternatively, or additionally, the battery module 800 may include oneor more capacitors or supercapacitors. In some embodiments in which thebattery module 800 is defined by a plurality of battery units, the powermanagement system 830 may include one or more battery disconnect unitsconfigured to selectively electrically couple/decouple one or more ofthe battery units from the rest of the power management system 830. Thebattery module 800 of the power management system 830 may be definedhaving any desired capacity. For example, in some embodiments, thebattery module 800 may have a capacity of approximately 300 kilowatthours. In other embodiments, the battery module 800 may have a capacitygreater than or less than 300 kilowatt hours.

According to various embodiments, the power management system 830 mayinclude a battery management controller configured to control operationof the flow of current during charging of the battery module 800 and/orduring use of the battery module 800 to power the operation of any oneor more components of the concrete mixer truck 10. The batterymanagement controller may comprise any number of switches or otherelements configured to selectively couple and/or decouple one or morecomponents of the power management system 830 from other components ofthe power management system 830, such as, e.g., the battery module 800.In various embodiments, the battery management controller may beconfigured to selectively couple and/or decouple the various componentsof the power management system 830 so as to enable operation of theconcrete mixer truck 10 according to any number of different operatingmodes, including any of the various operating modes described below withreference to FIGS. 67-69D. In embodiments in which the battery module800 is defined by a plurality of battery units connected to one anothervia one or more battery disconnect units, the battery managementcontroller may also optionally be configured to provide selectivecontrol over the operation of the battery disconnect units. In yet otherembodiments, the battery management controller may be configured toadditionally, or alternatively, also monitor the health of the batterymodule 800.

Referring to FIGS. 49-53, the battery module 800 further includes aseries of energy storage devices, shown as battery assemblies 820. Eachbattery assembly 820 is configured to store, and subsequently provide,electrical energy that is used to power the first electromagnetic device306 and the second electromagnetic device 308. The battery assemblies820 may contain one or more individual batteries (e.g., lithium ionbatteries, lead acid batteries, nickel-cadmium batteries, etc.) thatstore energy chemically. The battery assemblies 820 may additionally oralternatively include one or more capacitors or supercapacitors. Thebattery assemblies 820 are coupled to the battery module frame 810.Specifically, the battery assemblies 820 are placed atop the bottom twoof the base portions 812. As shown in FIGS. 51-53, two rows, each withseven battery assemblies 820, are placed atop each support plate 1104for a total of twenty eight battery assemblies 820. In otherembodiments, the battery module 800 includes more or fewer batteryassemblies 820. In one embodiment, the battery module 800 has a capacityof approximately 300 kilowatt hours. In other embodiments, the batterymodule 800 has a capacity greater than or less than 300 kilowatt hours.In some embodiments, each battery assembly 820 includes a batterycontroller configured to control operation of the battery assembly 820.By way of example, the battery controller may be configured to controlwhich battery cells are being charged and/or drawn from. By way ofanother example, the battery controller may be configured to interactwith one or more sensors to determine the health of the battery assembly820. In one embodiment, such a controller is controlled with a 24 voltcircuit.

Referring to FIGS. 54-56, the battery module 800 further includes apower management system 830 configured to condition, convert,distribute, or otherwise manage the electrical energy flowing to andfrom the battery assemblies 820. The power management system 830 iselectrically coupled to the battery assemblies 820, the charging port802, the first electromagnetic device 306, and the secondelectromagnetic device 308.

The power management system 830 includes a variety of power managementdevices electrically coupled to one another. The power management system830 includes a series of first power management devices, shown asbattery disconnect units 832. Each battery disconnect unit 832 isconfigured to selectively electrically decouple one or more of thebattery assemblies 820 from the rest of the power management system 830(i.e., isolate one or more of the battery assemblies 820). The batterydisconnect units 832 may be activated to isolate the battery assemblies820 during maintenance of the battery module 800. The power managementsystem 830 further includes a power management device, shown as inverter834. The inverter 834 is electrically coupled to the charging port 802and the battery assemblies 820. The inverter 834 is configured toconvert alternating current electrical energy from an outside powersource (e.g., the power grid, a generator, etc.) received through thecharging port 802 to direct current electrical energy to charge thebattery assemblies 820. The power management system 830 further includesa power management or power distribution device, shown as junction box836. The junction box 836 is configured to distribute electrical energythroughout the concrete mixer truck 10 (e.g., between the inverter 834,the battery assemblies 820, the first electromagnetic device 306, andthe second electromagnetic device 308, etc.). The junction box 836includes couplers, shown as bus bars 838 that electrically couplevarious components. The junction box 836 also includes power disconnectdevices (e.g., breakers, fuses, etc.), shown as fuses 840. The fuses 840are configured to electrically decouple components when the currentflowing therethrough exceeds a threshold level. The battery disconnectunits 832, the inverter 834, and the junction box 836 rest atop and arecoupled to the top one of the base portions 812.

Referring again to FIG. 11, the concrete mixer truck 10 further includesa power management device, shown as traction inverter 842. The tractioninverter 842 is coupled to the chassis 20 beneath the mixing drum 202.The traction inverter 842 is electrically coupled to the battery module800, the first electromagnetic device 306 and the second electromagneticdevice 308. Specifically, the traction inverter 842 is electricallycoupled to the battery assemblies 820. The traction inverter 842 isconfigured to convert direct current electrical energy from the batteryassemblies 820 to alternating current electrical energy to power thefirst electromagnetic device 306 and the second electromagnetic device308. In some embodiments, the traction inverter 842 is additionallyconfigured to convert alternating current electrical energy (e.g.,produced by the first electromagnetic device 306 and/or the secondelectromagnetic device 308 during regenerative braking, etc.) to directcurrent to recharge the battery assemblies 820.

When charging the battery assemblies 820, the charging port 802 isconfigured to receive alternating current electrical energy from anoutside source (e.g., the power grid, etc.) and supply the alternatingcurrent electrical energy to the inverter 834. In some embodiments, theinverter 834 is configured to receive 480 volt, three phase, alternatingcurrent electrical energy through the charging port 802. In someembodiments, the inverter 834 is configured to receive electrical energyat a current of up to 80 amps. The inverter 834 is configured to convertthe alternating current electrical energy to direct current electricalenergy, which is supplied to the battery assemblies 820 to charge thebattery assemblies 820.

When operating the concrete mixer truck 10, the battery assemblies 820are drained, providing direct current electrical energy to the tractioninverter 842. The traction inverter 842 converts the direct currentelectrical energy from the battery assemblies 820 to alternating currentelectrical energy, which is supplied to the first electromagnetic device306 and/or the second electromagnetic device 308 to power the powerplant module 302. In one embodiment, the first electromagnetic device306 and the second electromagnetic device 308 are configured to receive700 volt alternating current electrical energy.

Traction Inverter

The traction inverter 842 is configured to transfer energy stored in thebattery module 800 to the traction motor 1304 to provide power to thetractive assembly of the concrete mixer truck 10 during transport. Inembodiments in which the traction motor 1304 is powered using analternating current, the traction inverter 842 is configured to convertdirect current from the battery module 800 into the alternating currentused by the traction motor 1304. According to various embodiments, thetraction motor 1304 may be configured to receive 700-volt alternatingcurrent electrical energy from the traction inverter 842. In someembodiments, the traction inverter 842 is configured to receiveelectrical energy at a current of up to 80-amps.

Referring to FIG. 57, one exemplary embodiment of a traction inverter842 that may be utilized in the power management system 830 isillustrated. As illustrated by FIG. 57, according to variousembodiments, the traction inverter 842 may be defined as a dual-threephase H-bridge inverter having a DC input 21 and two motor outputs 23.As also illustrated by the traction inverter 842 embodiment of FIG. 57,according to various embodiments, the traction inverter 842 mayoptionally additionally include any one or more of: a brake choppercircuit 1325 and brake chopper output 1327, DC-bus capacitors 1329,balance/bleed resistors 1331, a DC-bus voltage measurement circuit 1333;EMI filters 1335, etc. As will be understood, according to otherembodiments, any number of other, different traction inverter 842arrangements may be used as desired.

As noted above, according to various embodiments, the power managementsystem 830 is configured to minimize the components required to powerthe concrete mixer truck 10 to advantageously minimize both costs andadditional weight associated with the incorporation of additionalelements into a vehicle by reutilizing one or more of the components ofthe power management system 830 to serve different functions duringdifferent operating modes of the concrete mixer truck 10. Accordingly,in addition to being used to convert direct current received from thebattery module 800 into alternating current that is supplied to thetraction motor 1304, according to various embodiments the tractioninverter 842 may additionally be used during the charging of the batterymodule 800 using externally sourced electrical energy received via thecharging port 802.

In particular, the power management system 830 may be configured toreceive externally sourced electrical energy (either as alternatingcurrent or as direct current) via the charging port 802 from an externalpower grid or other source. In some embodiments, the charging port 802may be configured to receive 480-volt, three phase alternating currentto power the battery module 800. The charging port 802 may be configuredto receive electrical energy from Level 1, Level 2, and/or Level 3charging stations and/or any other source of electric energy. As will bedescribed in more detail below, the traction inverter 842 alone, oroptionally in combination with one or more of the filtering or othercharge modifying elements (e.g., motor windings, inductors, diodes,etc.) optionally included as part of the power management system 830,may be used to convert the received externally sourced electrical energyinto direct current which may be used to charge the battery module 800.

As noted above, according to some embodiments, the power managementsystem 830 may additionally include the drum drive motor 252 and drumdrive inverter 1306 of the concrete mixer truck 10. According to somesuch embodiments, the power management system 830 may include anadditional charging port 802 configured to receive externally sourcedalternating current and/or direct current that may be use to power thedrum drive motor 252 and/or to charge the battery module 800 during oneor more operating modes of the concrete mixer truck 10.

Alternatively, in order to further minimize the amount of components ofthe concrete mixer truck 10, according to some embodiments, the batterymanagement controller may be configured to allow for the selectivecoupling of the traction inverter 842 to the drum drive motor 252. Aswill be understood, according to such embodiments, the drum driveinverter 1306 may optionally be omitted from the concrete mixer truck10. Additionally, or alternatively, in some embodiments, the batterymanagement controller may be configured to selectively couple the mixingassembly of the concrete mixer truck to the traction motor 1304,allowing the operation of the mixing assembly to be effectuated usingthe traction motor 1304, and thus allowing one or both of the drum driveinverter 1306 and/or drum drive motor 252 to be omitted from theconcrete mixer truck 10.

Turning to FIGS. 57-66, power management system 830 topologies accordingto a variety of exemplary embodiments are illustrated. As discussedabove, according to various embodiments, externally sourced alternatingcurrent and/or direct current is supplied to the power management system830 via the charging port 802. As shown in FIG. 58, according to variousembodiments, a traction inverter 842, such as, e.g., the tractioninverter 842 illustrated in the embodiment of FIG. 57, may operate topass externally received direct current received at a motor output 1323of the traction inverter 842 to the battery module 800 at a voltagelevel input equal to that of the externally sourced direct current inputinto the power management system 830. As shown in FIG. 59, in someembodiments, the traction inverter 842 may operate to rectify externallysourced alternating current input into the motor output 1323 of thetraction inverter 842, with the rectified direct current output by thetraction inverter 842 having a voltage level equal to that of theexternally sourced alternating currently received via the charging port802.

Alternatively, as noted above, according to various embodiments, one ormore filters or other charge modifying elements (e.g., motor windings,inductors, diodes, etc.) included as part of the power management system830 may be used with (or as a part of) the traction inverter 842 duringthe charging of the battery module 800 to filter or otherwise modify theelectrical charge input into the power management system 830 viacharging port 802. According to various embodiments, some or all of thetraction inverter 842 and/or other power management system 830 elementsused during battery module 800 charging may also be used to filter orotherwise modify the direct current supplied by the battery module 800to the traction inverter 842 during operation of the concrete mixertruck 10 in a transport mode.

For example, as illustrated by the various power management system 830topologies of FIGS. 60-66, in various embodiments, together with thetraction inverter 842, the one or more additional power managementsystem 830 elements (and/or reutilized portions of one or more existingpower management system 830 components) may be configured to: maintainthe DC-link voltage supplied to and/or received from the battery module800 at a constant voltage; provide the power management system 830 withboost/buck functionality that allows surplus energy (generated e.g., asa result of regenerative braking) to be stored and subsequently used tooperate the concrete mixer truck 10; regulate current and/or voltagesupplied to the battery so as to, e.g., prevent overcharging of thebattery module 800 using pulse width modulation; etc.

As shown in FIG. 60, according to some embodiments, a power managementsystem 830 including a traction inverter 842 such as, e.g. thatillustrated by the embodiment of FIG. 57, may be provided withbuck/boost capability via the incorporation of an external diode 1337and inductor 1339. Turning to FIG. 61, according to another embodiment,any number of DC-DC converters 1341 (e.g., forward, flyback,non-isolated, isolated, bi-directional, etc.) may be utilized with thetraction inverter 842 to regulate voltage to the DC-link.

Referring to FIG. 62A, in some power management system 830 embodiments,boost and bucking of charge voltage may be achieved by modifying thetraction inverter 842 illustrated in FIG. 57 by replacing the brakechopper circuit 1325 with an additional IGBT module 1343, adding aninductor 1339 to the brake chopper output 1327, and attaching thebattery module 800 to the brake chopper output 1327. As shown in FIGS.62B-62E, according to such embodiments, the power management system 830may be configured to operate in a boost mode in which the inductor ischarged (representatively illustrated in FIG. 62B); a charging mode inwhich energy stored in the inductor is supplied to the DC-link(representatively illustrated in FIG. 62C); a buck mode in which surplusenergy from the power management system 830 is transferred to thebattery module 800, such as, e.g., may occur as a result of regenerativebraking (representatively illustrated in FIG. 62D); and a fourth mode asrepresentatively illustrated in FIG. 62E.

As shown in FIG. 63 according to some embodiments, externally sourceddirect current may be fed into the brake chopper output 1327 of atraction inverter 842 similar to the traction inverter 842 of theembodiment of FIG. 62, with the brake chopper circuit 1325 of thetraction inverter 842 being used for pulse width modulation to regulatecurrent and/or voltage supplied to the battery module 800.

According to other embodiments, the power management system 830 mayoptionally include an AC filter. Illustrated in FIGS. 64 and 65 arerepresentative embodiments of power management system 830 topologiesincorporating such an AC filter. As shown in FIGS. 64 and 65, the powermanagement system 830 may include a traction inverter 842 similar tothat of the embodiment FIG. 57, with the exception of the brake choppercircuit 1325 is replaced with an additional IGBT module 1343. In each ofthe embodiments of FIG. 64 and FIG. 65, the externally sourcedalternating current received via the charging port 802 is shown as beinginput into the brake chopper output 1327 of the traction inverter 842.

As illustrated in FIG. 64, according to some embodiments, the AC filtermay be provided in the form of an additional inductor 1339 provide inseries between the brake chopper output 1327 and the additional IGBTmodule 1343. Alternatively, as illustrated by the embodiment of FIG. 65,in some embodiments, the power management system 830 may alternativelyreutilize the windings 1345 of the traction motor 1304 as an AC filter.In such embodiments, when in a charging mode, the brake managementcontroller may optionally be configured to electrically decouple thetraction motor 1304 from the motor output 1323 of the traction inverter842, and instead couple the traction motor 1304 to the brake chopperoutput 1327 as shown in FIG. 65. Referring to FIG. 66, yet another powermanagement system 830 topology including an inductor 1339 is illustratedaccording to another embodiment.

Although the coils in the power management system 830 topologiesillustrated in FIGS. 62A, 64, and 65 have been described as inductors1339, according to various embodiments, the coils in these powermanagement systems 830 may alternatively be used as transformers,thereby allowing the power management system 830 to be isolated from theexternally sourced electrical energy during charging of the batterymodule 800. According to some such embodiments, such isolation of thepower management system 830 from the externally sourced electricalenergy may advantageously allow the power management system 830 to actas a Level 3 supercharger, via which externally sourced alternatingcurrent received at a voltage of, e.g., 120-volts or 240-volts, via thecharging port 802 may be used to fast charge the battery module 800 byrectifying and boosting the received alternating current into directcurrent having a voltage of, e.g., approximately 480-volts or greater.

As will be understood, any additional number of power management system830 topologies, including any number of additional features and/orcombinations of elements, may be used to operate the concrete mixertruck 10. For example, according to various embodiments, any of thepower management system 830 embodiments as representatively illustratedin FIGS. 58-66 may incorporate traction inverters 842 having topologiesdifferent than that of the traction inverter 842 embodiment illustratedin FIG. 57.

Furthermore, as noted above, according to various embodiments, the powermanagement system 830 may optionally also include the drum driveinverter 1306 and drum drive motor 252 of the concrete mixer truck 10.Accordingly, in various embodiments, any of the power management system830 topologies illustrated in and described with reference to FIGS.58-66 may optionally also be modified to include the drum drive inverter1306 and/or drum drive motor 252 of the concrete mixer truck 10. In suchembodiments, the drum drive inverter 1306 may be defined by a topologysimilar to that of the traction inverter 842, or may be defined by anynumber of other topologies.

Operational Modes

As described above, the power management system 830 may be configured(using, e.g., the battery management controller) to operate the concretemixer truck 10 according to any number of different operating modesthrough the selective coupling and decoupling of one or more of thecomponents of the power management system 830. According to variousembodiments, the concrete mixer truck 10 may be operated according to: acharging mode, a transport mode, and one or more mixing modes. In someembodiments, the concrete mixer truck 10 may additionally be operatedaccording to an optional regenerative mode and/or vehicle-2-grid mode,so as to allow the concrete mixer truck 10 to take advantage of anysurplus energy that may be generated during operation of the concretemixer truck 10 (e.g., energy generated as a result of regenerativebraking).

As illustrated by the exemplary embodiment of FIG. 67, in the chargingmode, the battery module 800 may be charged using externally sourcedalternating current or direct current. As noted above, the charging port802 of the power management system 830 may be configured to receivealternating current and/or direct current. As also noted above,according to various embodiments, any of the power management system 830topologies discussed above, or any other number of power managementsystem 830 topologies may be used to charge the battery module 800 usingthe externally sourced electrical energy received via the charging port802.

The externally sourced alternating current or direct current may bereceived by the charging port 802 from any number of different externalchargers, including Level 1, Level 2, or Level 3 external chargers. Asdiscussed above, according to various embodiments, the power managementsystem 830 provided by the concrete mixer truck 10 may advantageously beconfigured to function as an onboard Level 3 charger in which externallysourced alternating current received at a voltage of, e.g., 120-volt or240-volt (received, e.g., from a Level 2 external charger) may beconverted into direct current having, e.g., a voltage up to or greaterthan 480-volts, thus enabling fast charging of the battery module 800.By configuring the power management system 830 to operate as an onboardLevel 3 fast charger, DC-fast charging of the concrete mixer truck 10may be accomplished using a standard Level 2 external charger. As willbe understood, such an arrangement may allow for fast charging of theconcrete mixer truck 10 irrespective of the availability and/oraccessibility of a Level 3 external supercharging station.

As illustrated by the various representative power management system 830topologies of FIGS. 58-64 and FIG. 66, according to various embodiments,the externally sourced alternating current or direct current received bythe charging port 802 may be fed directly into the traction inverter 842via any of the motor output 1323, brake chopper output 1327, and/or DCinput 21 of the traction inverter 842. Alternatively, asrepresentatively illustrated by the power management system 830embodiment of FIG. 65, in some embodiments, the externally sourcedelectrical energy may be fed to the traction inverter 842 via thewindings 1345 of the traction motor 1304. In such embodiments, thetraction motor 1304 may optionally be configured to be disengaged fromthe battery module 800 (using, e.g., the battery management controller)during the charging mode for safety purposes.

In embodiments in which the power management system 830 optionallyincludes the drum drive motor 252 and/or drum drive inverter 1306 of theconcrete mixer truck 10, charging of the battery module 800 mayadditionally, or alternatively, be effectuated by supplying externallysourced electrical energy received from the charging port 802 directlyto the drum drive inverter 1306 and/or to the drum drive motor 252.According to some such embodiments, the power management system 830 maycomprise a single charging port 802 that may selectively be coupled(using, e.g., the battery management controller) to the tractioninverter 842 (directly or via the traction motor 1304), and/or to thedrum drive inverter 1306 (directly or via the drum drive motor 252). Inother embodiments, the power management system 830 may include aplurality of charging ports 802, with a first charging port 802 beingconfigured to deliver externally sourced electrical energy to thetraction inverter 842 (directly or via the traction motor 1304) and asecond charging port 802 being configured to deliver externally sourcedelectrical energy to the drum drive inverter 1306 (directly or via thedrum drive motor 252). In yet other embodiments, the power managementsystem 830 may optionally include the drum drive motor 252, with thetraction inverter 842 being configured to be used with each of the drumdrive motor 252 and the traction motor 1304. In some such embodiments,externally sourced electrical energy received by one or more chargingports 802 may be fed into the traction inverter 842 via either thetraction motor 1304 or the drum drive motor 252 during charging of thebattery module 800.

Referring to FIG. 68, in the transport mode, energy stored in thebattery module 800 is transferred to the traction inverter 842 as directcurrent, which may then be converted by the traction inverter 842 topower the traction motor 1304.

As illustrated by the representative embodiments of FIGS. 69A-69D, theconcrete mixer truck 10 may be configured to operate according to one ormore mixing modes. In certain situations, an external charger or powersource may not be available at the location at which concrete is to bemixed and dispensed by the concrete mixer truck 10. Accordingly, asshown in FIG. 69A, in various embodiments, the concrete mixer truck 10may include a battery-powered mixing mode in which energy stored in thebattery module 800 is transferred to the drum drive inverter 1306 asdirect current, which may then be converted by the drum drive inverter1306 to power the drum drive motor 252. As will be understood, inembodiments in which the traction inverter 842 alone, or in combinationwith the traction motor 1304, is configured to power both the tractiveassembly and the mixing assembly of the concrete mixer truck 10, thebattery management controller may be configured to selectively couplethe traction inverter 842 (and optionally the traction motor 1304) toeach of the tractive assembly and the mixing assembly of the concretemixer truck.

In certain situations, an external charger configured to deliverexternally sourced alternating current and/or direct current to thepower management system 830 may be available at a location at which theconcrete mixer truck 10 is to be used to mix and/or dispense concrete.Accordingly, as illustrated in FIG. 69B, in various embodiments, inorder to conserve the power stored by the battery module 800, the powermanagement system 830 may be operated according to an externally-poweredmixing mode in which the operation of the mixing assembly is partially,or entirely, powered using the external power source.

In such embodiments, externally sourced alternating current may besupplied by the charging port 802 directly to the drum drive motor 252,or may alternatively optionally be routed by the battery managementcontroller through one or more filter or other current and/or voltagemodifying elements prior to delivering the alternating current to thedrum drive motor 252. In embodiments in which the external charger isconfigured to provide the power management system 830 with directcurrent, the battery management controller may be configured to routethe direct current received via the charging port 802 through the drumdrive inverter 1306 (which may be the same as, or discrete from thetraction inverter 842) and one or more optional filter and/or othercharge modifying elements.

As shown in FIG. 69B, according to some embodiments of theexternally-powered mixing operating mode, the external charger may beused exclusively to power the operation of the drum drive motor 252.Alternatively, as illustrated in FIGS. 69C and 69D, in variousembodiments, the externally-powered mixing mode may define a combinedmixing/charging mode in which the externally sourced alternating currentor direct current may be used to both charge the battery module 800 andto power the drum drive motor 252. According to some such combinedmixing/charging operating mode embodiments, the battery managementcontroller may be configured to simultaneously route the externallysourced electrical charge to each of the battery module 800 and the drumdrive motor 252. In other such combined mixing/charging operating modeembodiments, the battery management controller may be configured toalternate the delivery of the externally sourced alternating current ordirect current to each of the battery module 800 and the drum drivemotor 252.

As illustrated in FIG. 69C, in some embodiments in which the powermanagement system 830 includes a first charging port 802 configured todeliver externally sourced electrical charge to the traction inverter842 (either directly or via the traction motor 1304) and a secondcharging port 802 configured to deliver externally source electricalcharge to the drum drive inverter 1306 (either directly or via the drumdrive motor 252), the combined mixing/charging operating mode mayinclude operating the battery management controller to utilizeelectrical energy received via the first charging port 802 to charge thebattery module 800, and utilizing the second charging port 802 to powerthe drum drive motor 252. Alternatively, as illustrated in FIG. 69D,electrical energy received via the first charging port 802 may be usedto both charge the battery module 800 and to power the drum drive motor252.

As described above, in certain situations, (e.g. during braking of theconcrete mixer truck 10), the operation of the concrete mixer truck 10may result in surplus energy being delivered to the power managementsystem 830. Accordingly, in various embodiments, the power managementsystem 830 may advantageously include a power regeneration mode in whichthe surplus energy may be stored by the battery module 800 for futureuse by the concrete mixer truck 10. According to some embodiments inwhich the power management system 830 is configured to be operatedaccording to an optional vehicle-2-grid mode, the surplus energy storedin the battery module 800 (and/or energy stored in the battery module800 from a prior charging of the battery module 800) may be fed into thegrid via the charging port 802.

Temperature Management

Throughout operation of the concrete mixer truck 10 (e.g., charging ofthe battery assemblies 820, driving of the first electromagnetic device306 and the second electromagnetic device 308, etc.), electricityflowing throughout the battery module 800 experiences resistance,generating thermal energy. Referring to FIGS. 51, 52, 54, and 70, toprevent the thermal energy from damaging components of the batterymodule 800, the battery module 800 further includes a temperatureregulation assembly, shown as cooling system 850. The cooling system 850is configured to remove thermal energy from components of the batterymodule 800 and expel the thermal energy into the surrounding atmosphere.In one embodiment, the cooling system 850 is entirely contained withinthe battery module 800.

The cooling system 850 includes a driver, shown as coolant pump 852,which is configured to circulate a coolant (e.g., water, a mixture ofwater and antifreeze, etc.) throughout the cooling system 850. In someembodiments, the coolant pump 852 is an electrically driven pump that ispowered by electrical energy from the battery assemblies 820 and/or thebattery 642. The coolant pump 852 is fluidly coupled to a reservoir,shown as coolant tank 854. The coolant tank 854 is configured to store avolume of the coolant for use in the rest of the cooling system 850. Insome embodiments, the coolant tank 854 includes an aperture thatfacilitates adding coolant to the cooling system 850. Conduits, such aspipes or hoses, may be used to fluidly couple the components of thecooling system 850 (e.g., to fluidly couple the coolant pump 852 and thecoolant tank 854, etc.).

Each of the battery assemblies 820 includes a heat transfer device,shown as heat sink 856. Each heat sink 856 includes a coolant passagefluidly coupled to the coolant pump 852 such that the coolant passesthrough the heat sink 856. The heat sinks 856 include a thermallyconductive material (e.g., copper, aluminum, steel, etc.) extendingbetween the portions of the battery assemblies 820 that generate thethermal energy (e.g., the battery cells, etc.) and the coolant passage.The heat sinks 856 are configured to transfer the thermal energy fromthe battery assembly 820 to the coolant within the coolant passage,heating the coolant. The heated coolant then flows out of the heat sink856, removing the thermal energy from the battery assembly 820. Theinverter 834 also includes a heat sink 856 configured to transferthermal energy from the inverter 834 into the coolant. In otherembodiments, other components of the battery module 800 (e.g., thebattery disconnect units 832, etc.) include heat sinks 856 fluidlycoupled to the coolant pump 852.

The heat sinks 856 are fluidly coupled to a heat transfer device, shownas radiator assembly 860, such that the radiator assembly 860 receivesthe heated coolant. The radiator assembly 860 is configured to transferthermal energy from the heated coolant to the atmosphere surrounding theradiator assembly 860, cooling the coolant. In one embodiment, theradiator assembly 860 includes a radiator having fins formed from aconductive material. The fins are configured to increase the surfacearea of the radiator that is contacted by air from the surroundingatmosphere, maximizing heat transfer from the coolant to the air. Theradiator assembly 860 may also include a fan that forces air across theradiator, further increasing the heat transfer. After the coolant iscooled by the radiator assembly 860, the coolant passes back through thecoolant tank 854 and to the coolant pump 852, which recirculates thecoolant through the cooling system 850.

The cooling system 850 may include other components that facilitateoperation and maintenance of the cooling system 850. As shown in FIGS.70 and 71, the cooling system 850 includes flow dividers or flowuniters, shown as manifolds 862. One manifold 862 is configured to splitthe flow of coolant from the radiator assembly 860 into multiple flowpaths, each flowing through a separate group of the heat sinks 856. Inone embodiment, the manifold 862 splits the flow into five paths: onepath flowing through the heat sink 856 of the inverter 834 and fourpaths each flowing through a subset of the heat sinks 856 of the batteryassemblies 820. After the coolant flows through the heat sinks 856, asecond manifold 862 reunites the flows prior to the coolant entering thecoolant tank 854. In other embodiments, the coolant flows alongdifferent flow paths between the radiator assembly 860 and the coolantpump 852. The cooling system 850 may additionally include one or moremeasurement devices. As shown in FIG. 56, the cooling system 850includes pressure gauges 864 configured to measure the pressure of thecoolant at various points in the cooling system 850. As shown in FIG.71, the cooling system 850 further includes flowmeters 866 configured tomeasure the flow rate of coolant along each of the split flow paths.

The present disclosure contemplates methods, systems, and programproducts on any machine-readable media for accomplishing variousoperations. The embodiments of the present disclosure may be implementedusing existing computer processors, or by a special purpose computerprocessor for an appropriate system, incorporated for this or anotherpurpose, or by a hardwired system. Embodiments within the scope of thepresent disclosure include program products comprising machine-readablemedia for carrying or having machine-executable instructions or datastructures stored thereon. Such machine-readable media can be anyavailable media that can be accessed by a general purpose or specialpurpose computer or other machine with a processor. By way of example,such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, CD-ROMor other optical disk storage, magnetic disk storage or other magneticstorage devices, or any other medium which can be used to carry or storedesired program code in the form of machine-executable instructions ordata structures and which can be accessed by a general purpose orspecial purpose computer or other machine with a processor. Wheninformation is transferred or provided over a network or anothercommunications connection (either hardwired, wireless, or a combinationof hardwired or wireless) to a machine, the machine properly views theconnection as a machine-readable medium. Thus, any such connection isproperly termed a machine-readable medium. Combinations of the above arealso included within the scope of machine-readable media.Machine-executable instructions include, for example, instructions anddata which cause a general purpose computer, special purpose computer,or special purpose processing machines to perform a certain function orgroup of functions.

As utilized herein, the terms “approximately,” “about,” “substantially,”and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numerical ranges provided. Accordingly, these terms shouldbe interpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and claimedare considered to be within the scope of the invention as recited in theappended claims.

It should be noted that the terms “exemplary” and “example” as usedherein to describe various embodiments is intended to indicate that suchembodiments are possible examples, representations, and/or illustrationsof possible embodiments (and such term is not intended to connote thatsuch embodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” “connected,” and the like, as used herein, mean thejoining of two members directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent, etc.) or moveable (e.g.,removable, releasable, etc.). Such joining may be achieved with the twomembers or the two members and any additional intermediate members beingintegrally formed as a single unitary body with one another or with thetwo members or the two members and any additional intermediate membersbeing attached to one another.

References herein to the positions of elements (e.g., “top,” “bottom,”“above,” “below,” “between,” etc.) are merely used to describe theorientation of various elements in the figures. It should be noted thatthe orientation of various elements may differ according to otherexemplary embodiments, and that such variations are intended to beencompassed by the present disclosure.

Also, the term “or” is used in its inclusive sense (and not in itsexclusive sense) so that when used, for example, to connect a list ofelements, the term “or” means one, some, or all of the elements in thelist. Conjunctive language such as the phrase “at least one of X, Y, andZ,” unless specifically stated otherwise, is otherwise understood withthe context as used in general to convey that an item, term, etc. may beeither X, Y, Z, X and Y, X and Z, Y and Z, or X, Y, and Z (i.e., anycombination of X, Y, and Z). Thus, such conjunctive language is notgenerally intended to imply that certain embodiments require at leastone of X, at least one of Y, and at least one of Z to each be present,unless otherwise indicated.

It is important to note that the construction and arrangement of thesystems as shown in the exemplary embodiments is illustrative only.Although only a few embodiments of the present disclosure have beendescribed in detail, those skilled in the art who review this disclosurewill readily appreciate that many modifications are possible (e.g.,variations in sizes, dimensions, structures, shapes and proportions ofthe various elements, values of parameters, mounting arrangements, useof materials, colors, orientations, etc.) without materially departingfrom the novel teachings and advantages of the subject matter recited.For example, elements shown as integrally formed may be constructed ofmultiple parts or elements. It should be noted that the elements and/orassemblies of the components described herein may be constructed fromany of a wide variety of materials that provide sufficient strength ordurability, in any of a wide variety of colors, textures, andcombinations. Accordingly, all such modifications are intended to beincluded within the scope of the present inventions. Othersubstitutions, modifications, changes, and omissions may be made in thedesign, operating conditions, and arrangement of the preferred and otherexemplary embodiments without departing from scope of the presentdisclosure or from the spirit of the appended claims.

What is claimed is:
 1. A concrete mixer truck, comprising: a chassis; aplurality of tractive assemblies coupled to the chassis; a mixing drumrotatably coupled to the chassis, the mixing drum defining an internalvolume configured to contain material and an aperture through which thematerial can enter and exit the internal volume; an energy storagedevice positioned at a rear end of the chassis and configured to provideelectrical energy; and an electromagnetic device electrically coupled tothe energy storage device, wherein the electromagnetic device isconfigured to receive the electrical energy from the energy storagedevice and provide mechanical energy to drive at least one of theplurality of tractive assemblies to propel the concrete mixer truck. 2.The concrete mixer truck of claim 1, wherein at least one of theplurality of tractive assemblies is a rear axle assembly, wherein acenter of gravity of the energy storage device is positioned rearward ofthe rear axle assembly.
 3. The concrete mixer truck of claim 1, whereinthe electromagnetic device is configured to generate electrical energyto charge the energy storage device.
 4. The concrete mixer truck ofclaim 1, further comprising a trailer coupled to the rear end of thechassis and configured to be towed by the concrete mixer truck, thetrailer comprising a frame and a plurality of tractive assemblies,wherein the energy storage device is coupled to the frame of thetrailer.
 5. The concrete mixer truck of claim 4, wherein the trailer isreleasably coupled to the rear end of the chassis in a fixed positionand orientation relative to the chassis of the concrete mixer truck. 6.The concrete mixer truck of claim 1, wherein the energy storage devicecomprises a frame and one or more battery assemblies, the frameconfigured to support the one or more battery assemblies.
 7. Theconcrete mixer truck of claim 6, wherein the energy storage devicefurther comprises a cooling system configured to remove thermal energyfrom the one or more battery assemblies.
 8. The concrete mixer truck ofclaim 1, wherein the concrete mixer truck is a front discharge concretemixer truck, the concrete mixer truck further comprising a chuteassembly positioned at a front end of the concrete mixer truck.
 9. Theconcrete mixer truck of claim 1, further comprising an accessory module,the accessory module comprising one or more power transfer devices,wherein the electromagnetic device is further configured to providemechanical energy to operate the accessory module.
 10. A concrete mixertruck, comprising: a frame; a cab coupled to the frame; a mixing drumcoupled to the frame; and a power plant module coupled to the frame, thepower plant module comprising: an electromagnetic device electricallycoupled to a battery module, the battery module configured to storeelectrical energy and positioned at a rear end of the concrete mixertruck such that a weight of the battery module offsets a weight of thecab, a weight of the power plant module, and a weight of the mixingdrum, the electromagnetic device configured to receive electrical energyfrom the battery module and provide mechanical energy; and atransmission coupled to the electromagnetic device and configured totransfer a first portion of the mechanical energy from theelectromagnetic device to at least one of a plurality of tractiveassemblies to propel the concrete mixer truck.
 11. The concrete mixertruck of claim 10, wherein at least one of the plurality of tractiveassemblies is a rear axle assembly, wherein a center of gravity of theenergy storage device is positioned rearward of the rear axle assembly.12. The concrete mixer truck of claim 10, wherein the electromagneticdevice is configured to generate electrical energy to charge the energystorage device.
 13. The concrete mixer truck of claim 10, wherein theenergy storage device comprises a frame and one or more batteryassemblies, the frame configured to support the one or more batteryassemblies.
 14. The concrete mixer truck of claim 13, wherein the energystorage device further comprises a cooling system configured to removethermal energy from the one or more battery assemblies.
 15. The concretemixer truck of claim 10, further comprising an accessory module coupledto the transmission, the accessory module comprising one or more powertransfer devices, wherein the transmission is configured to transfer aportion of the mechanical energy from the electromagnetic device to theaccessory module.
 16. The concrete mixer truck of claim 10, furthercomprising a trailer coupled to the rear end of the frame and configuredto be towed by the concrete mixer truck, the trailer comprising a frameand a plurality of tractive assemblies, wherein the battery module iscoupled to the frame of the trailer.
 17. A battery system for a concretemixer truck, the battery system comprising a frame and one or morebattery assemblies, wherein: the battery system is coupled to a rear endof the concrete mixer truck such that a center of gravity of the batterysystem is positioned rearward of a rear axle assembly of the concretemixer truck; and the battery system is configured to provide electricalenergy to one or more electromagnetic devices of the concrete mixertruck, the one or more electromagnetic devices configured to drive oneor more tractive assemblies of the concrete mixer truck.
 18. The systemof claim 17, further comprising a plurality of engagement membersconfigured to releasably couple the battery system to a frame of theconcrete mixer truck.
 19. The system of claim 17, further comprising acooling system configured to remove thermal energy from the one or morebattery assemblies.
 20. The system of claim 17, wherein the one or moreelectromagnetic devices are further configured to provide charge thebattery system.